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October 11, 201310/25/2013 111 October 14, 2013 Modification Procedures for Predl Manhole Base Liners
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Modification Procedures for
Predl Manhole Base Liners
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Procedure For Modifying A FRP Lined
Manhole Base
The following procedure outlines the steps to suc-cessfully modify an FRP lined manhole base. This document applies to Fiberglass Reinforced Polymer (FRP) Base Liners in any diameter.
This process does not apply to Base Liners con-structed from Polypropylene (PP). Please refer to the Predl Field Guide which informs you how to dis-tinguish between FRP and PP material.
Please call Predl Systems at 1-855-773-3562 or contact us at www.predlsystems.com if you require clarification or support.
Technical Specifications — Adding a
Channel to Existing FRP Base Liner
It is possible to add a channel to nearly any lined base with a Predl FRP Base Liner. Predl Systems can provide channels in virtually any configuration required. Replacement channels are typically sup-plied as a channel in a straight section to match a cored opening. The replacement channel includes a socket to accept the spigot end of the Predl bell. Contact Predl Systems at 1-855-773-3652 to order replacement channels and bells.
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Spigot
Socket
FRP
Concentric Ring Pattern
on PP Base Liners
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1. Identify the baseliner material using the instruc-tions on the page 1 and page 2.
2. Establish the alignment and elevation of the new connection that is to be made and Core an open-ing into the main channel. (see below)
3. Predl Systems recommends using a coring ma-chine to create a channel at least one nominal pipe size larger than the new incoming connec-tion (e.g. minimum 10” (250mm) core for an 8” (200mm) channel).
4. If a coring machine is unavailable, it is possible to create a rough core using a cutoff wheel with a masonry blade and an impact hammer.
5. Cut approximately 1” (25mm) through the base liner tracing the shape of the new channel and chisel out the underlying concrete beneath the liner section to be removed.
Pre-Formed Channel Liner Installation
1. Once the channel is cored, cut the channel liner to fit. Final precise cuts can be made once the channel is grouted in place. FRP channels cut best with a cut-off wheel in an angle grinder.
2. The core can receive a standard "Kor-N-Seal" flexible boot connector OR a Predl Gasketed FRP Bell. Grout in the bell from the outside of the manhole.
3. Use a Portland expanding non-shrink un-sanded grout approved by Predl Systems and the juris-diction governing the manhole.
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4. Leave enough of the spigot end of the bell ex-posed to allow the channel socket to fit over.
5. If any signs of ground water infiltration are present the area should be treated by chemical injection with a flexible water activated polyurethane grout.
6. After the structure is watertight install stainless steel pins into the host concrete to act as addition-al retention for the new high strength non shrink grout that will form the new channel.
7. When working near areas of existing live flow a by-pass or flow through plug system may be re-quired. Much of the work can be done in a live flow condition but when using the actual fiberglass res-in the work conditions must be 100% dry in the areas where the new fiberglass is to be applied.
Dry pack grout along
the edge of spigot.
Dry pack grout
along the edge.
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8. Fit the channel over the bell spigot. Check for fit and proper flow in the channel. Trim and reset the channel as necessary. Use dry pack grout to seal off the lower gaps. Flowable grout will be poured around the channel and will leak from this area if not sealed.
9. Fill flowable grout up to the bench height. Let the grout set according to the grout manufacturer’s directions. Clean any excess grout away from the bench and channel.
10. Once the grout is set, trim off any excess chan-nel liner.
11. Prepare the liner surfaces for sealing the seams. Lightly grind the surfaces of the bench and chan-nel liners approximately 2” (50mm) wide on ei-ther side of the seams.
12. Grind just enough to roughen the surface and expose clean material. This will prepare the FRP liners for bonding. Remove any dust or debris before continuing.
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Pour grout in the top.
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12. The grouted seams for FRP base liners must be sealed with fiberglass mat and resin. Predl Sys-tems recommends a corrosion resistant polyes-ter or vinylester resin intended for liquid service and two layers of 1.5oz / yd2 (50 gram / m2) fi-berglass mat. Effectively this creates a minimum layer of 0.125” (3mm) of cured fiberglass. Roll out any air bubbles with an aluminum roller. Ap-ply gel coat to the exposed surfaces of the new seams. Resin and color matched gel coat is available from Predl Systems.
Field Layup of FRP
1. Establish the alignment and elevation of the new connection that is to be made and core the man-hole. Once the core is made through the man-hole and into the bench area the Predl liner in the affected area needs to be cut or ground out; and, the underlying concrete interior of the man-hole must be chipped out in the area of the new proposed channel alignment. The core can re-ceive a standard “Kor N Seal” boot shown in the figures opposite.
2. When the Predl fiberglass is trimmed back, and the interior concrete removed, the new pipe pen-etration and boot can be mudded and the new channel can be re-poured and shaped. If any signs of ground water infiltration are present the
area should be treated by chemical injection with a flexible water activated polyurethane grout. After the structure is watertight install stainless steel pins into the host concrete to act as
Finished Channel Seams
FRP
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additional retention for the new high strength non shrink grout that will form the new channel. In exist-ing live flow manholes a by-pass or flow through plug system may be required. Much of the work can be done in a “live” condition but for the actual fiber-glass work the conditions must be dry in the areas to receive the new fiberglass. This new concrete chan-nel must be poured low enough, and to the desired grade, to receive the new fiberglass without impact-ing the grade in the channel once the thickness of the fiberglass is added. Allow adequate cure time for the new concrete before beginning the fiberglass procedure. The new fiberglass to be installed shall consist of a heavy mat and a minimum of ¼” of res-in with the gel coat color matched to the existing Predl Systems’ liner. All surfaces will be blended, faired and transitioned so that no irregularities in flow, shape or color will be present. Once the fiber-glass has cured and has been inspected it may be put back into service.
The information and images contained in this document are the property of Predl Systems North America Inc. The information is provided on a confidential basis for a limited purpose. It may be used only with the permission of Predl Systems. Any reproduction, retransmission, dissem-ination or other use that a person may make of this document without direct permission from Predl Systems is prohibited. You may call Predl Systems at 1-855-773-3562 or contact us at predlsystems.com to in-quire further about the complete terms and conditions for using this information.
Certified PREDL Field Service Providers:
British Columbia:
PREDLsystems North America Inc.
7520 Conrad St, Burnaby, BC V5A 2H7
Shane Pinkney
Field Service Technician Plastic Welder (SKZ) – DVS® 2212 Certified
NASSCO Certified Inspector of MH Rehab
Mobile: 604.615.1615
Florida:
Turner Lining Company
2998 Jacqueline Circle, DeLand, FL 32720
Wayne Turner Certified Underground Utility Contractor—FL License #CUC 055057
Confined Space Entry (OSHA Certified)
Plastic Welder (AGRU and PREDL Certified)
Mobile: 386.804.1898
Washington / Oregon:
Northwest Concrete Waterproofing
PO Box 908, Spanaway, WA 98387
Jon Rickabaugh WA NWCWLL #927M8
OR CCB #185993
Mobile: 253.686.1114
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Flow from two Inlets re-
channeled towards outlet.
