UV-Technology and CIPP-Liners shift the boundaries of sewer rehabilitation further and further

At the same time, CIPP liner manufacturers have developed their products to utilise these new opportunities using ProKASRO UV technology ensuring that rehabilitation of large diameter pipe profiles up to DN 1600 is today safe and economic.

In 2003 ProKASRO started to design, develop and manufacture KASRO UV systems from DN 150 to DN 1500, whether completely mobile, built into a vehicle or in a container. Since then ProKASRO has developed into a full-range supplier for complete sewer rehabilitation from Europe, via Asia to America. ProKASRO can accommodate any customer requirements and meet all construction site demands.

Using today’s state of the art technologies makes sewer rehabilitation via CIPP lining and UV-Technology within large diameters even more economically viable and efficient for both contractors and end users. In 2013 ProKASRO set a new milestone within the market of sewer rehabilitation. Tests with our newly developed KASRO UV light core 2 x 6 x 1000 W inside a sewer of DN 1500 were extremely positive. This set new standards which other suppliers could not reach and made the ProKASRO UV systems unrivalled for performance against other suppliers’ products. Samples were taken out of test liners and were tested for the E-modulus and the residual styrene in regards of the curing speed. The test showed an optimal pull through speed and curing of 60 cm per minute for the dimension of DN 1500. Other tests in that dimension even showed a curing speed of a DN 1500 CIPP liner with 80 cm per minute. The new KASRO UV light core creates conditions to cure liners larger than DN 1200 that are highly efficient, fast and safe. Through the option of combining up to three cores and expanding the cores power up to 18,000 Watts, it is now possible to halve the curing times.

The development of the new KASRO core for DN 1000 to DN 1500 and the technical progress of the KASRO core for DN 550 to DN 1000 have significantly contributed to that standard. Through an intelligent technique during expansion the UV-lamps move towards the laminate to an optimal distance for liner curing. The uncomplicated principle of the scissor lifting during core expansion makes the cores more stable and durable compared to the previous models. This adaptable design means that there is nothing to stand in the way of curing liners up to DN 2000.

Furthermore the lamps are distributed symmetrically around the core and are placed closer to the laminate. Through that the light curing of the liner gets more efficient as well as more consistent. A higher lamp performance is not even necessary to ensure a high-quality polymerisation during the curing process. The nearer the lamps get to the laminate, the faster it is being cured and with lower energy consumption.

Combining a UV control unit and a 200 m cable drum into a compact system, the new UV-CCU system intends to make sewer rehabilitation easy to execute, even within very narrow confines. Since the system’s launch in January 2015, ProKASRO has received a significant level of interest from both existing and potential clients, with ten units sold since product launch. The system is ideal for any business or contractor that can see and understand the benefits of having all functions and operations controlled from a single unit. With a maximum cable length of 200 m, the system can control a standard KASRO UV light source of 8 x 400/600 W for pipes ranging from 150-500 mm in diameter. For larger pipes ranging from 550-1,200 mm in diameter, the system can also accommodate a KASRO UV double core of 2 x 4 x 1000 W.

To ensure the UV light source is pulled back at a constant speed, thereby allowing the liner to be cured consistently, the complete curing operation of the CIPP liner is controlled via the systems’ integrated laptop located above the electrically driven cable drum. The on-screen display, visualizations and protocol data logging are also located there. A complete UV rehabilitation system in one unit with a minimum space outlay, the UV-CCU can be deployed from a work van, with the unit able to be deployed via lifting platform to job sites such as footpaths, cycle paths or alongside a railway line. According to ProKASRO, the system’s portability even allows UV curing work to occur in garages or halls, with the system able to be transported in an elevator or wheeled through doorways.

“With the UV-CCU weighing approximately 530 kg and mounted on four wheels, small job-sites become possible, such as installing a liner measuring only 15 m. It can even be moved by only one person”, said a company spokesperson.

The successful implementation of the mentioned projects shows that UV curing reached large diameters. However it is significant to match the used technology to the given circumstances of the jobsite. Especially for projects with special profiles in these dimensions it is important to ensure high-quality sewer rehabilitation. The demands placed on man, machine and technology have to be taken into consideration for the planning. Only through teamwork between the application engineers and the elaboration of feasible solutions it will be possible to shift the boundaries further on. It remains exciting what kind of ideas and innovations might be expected in the future.