The Complete Guide to Large-Scale CIPP Repairs: Challenges and Solutions

Looking to branch out into bigger CIPP repair jobs? You’re not alone, and there’s a need for teams that can tackle major sewer, water supply, and waste lines. But tackling a large-scale CIPP repair job comes with several challenges. Here’s how you can prepare.

Are Large-Scale CIPP Repairs Possible?

Over the last 20 years, CIPP repair technology has improved dramatically. The method itself is much the same, but the industry has been scaling toward larger projects for years now.

Today’s largest CIPP repair project was a 120-inch diameter repair of a steel-reinforced concrete drainage system under an airbase in New Jersey. The resin-impregnated liners alone weighed in at more than 80,000 pounds, and the project took nearly a year to complete.

But not all large-scale CIPP repairs are that big. Large-diameter pipes are generally considered anything about 16 inches in diameter. These pipe repairs may be easier to tackle than record-breaking diameters, but they still require special preparation, equipment, and knowledge.

Challenges with Large-Scale CIPP Repairs

Time, equipment, and logistics all play a role in the challenges that come with CIPP repairs for large-diameter pipes. For smaller CIPP repair companies, these are considerable obstacles to overcome. But with the right preparation, the right coordination, and the right equipment, it is still possible to take on a large-scale CIPP repair job successfully.

Scale

Working with large-diameter pipe repairs requires unique scaling solutions. Today, CIPP technology can address pipe diameters as high as 120 inches, but this kind of scale requires solutions beyond typical repairs.

CCTV inspections make this possible by providing complete visual inspections for large-diameter pipes and extensive pipe networks. Large robotic camera systems make inspections faster in these situations, and these inspections can be paired with ArcGIS technology to create digital maps for large projects.

Transportation

With projects that require hundreds of linear feet of large-diameter CIPP liners, crews will need workarounds for transportation. Moving wet-out liners that could weigh more than interstate and highway limits allow.

In these cases, the best solution is to manufacture and wet out liners on-site. While this presents other challenges, on-site prep is the most effective way to avoid transportation issues. It also solves another critical problem: premature curing.

Curing

CIPP resin curing is a heat-activated process. Once the resin reaches a certain temperature (often around 77°F), it begins to harden. CIPP liners, then, must be kept cool before installation. For large-scale sewer repairs, installation teams will need a way to keep the liners below activation temperatures until they’re ready to be installed.

One solution is building air-conditioned tents. These portable tents can provide the temperature control needed before installation while also being mobile enough to build and tear down as needed. Commercial air conditioning or refrigeration units are brought on-site to make this possible.

Another pre-installation solution is refrigerated trucks and trailers. These also provide an on-site solution to premature curing, but they may require extra costs for truck/trailer rental and fuel.

But even if the liner is kept cool before installation, curing during installation is still a significant challenge. With so much resin, hot-water curing requires special attention to maintain an even temperature.

Real-time digital monitoring systems provide the data needed to make changes to any inconsistencies in the curing process. These large-scale CIPP repairs will also need post-installation quality testing to ensure a complete repair, which is best completed by visual inspection via CCTV equipment.

Waste

Environmental contamination, as well as potential harm to the public, is a significant concern with CIPP repairs. Large-scale CIPP repairs require significant volumes of curing water, resins, and liners. When the job is completed, the excess materials must be disposed of properly.

For curing water and resins, hazardous waste protocols at the city and state levels must be followed. These change from job site to job site, so it’s important to research the requirements for a specific area before developing a waste disposal plan. Excess materials must also be disposed of properly. In many cases, liners will be custom fabricated for the job, but extra pieces (either before or after curing) must be taken from the site and disposed of within the required regulations.

Equipment

From transport vehicles to liner rollers, large-scale CIPP repairs will likely require equipment that few CIPP repair companies have on hand. And in extreme cases, the size of the liners may require a completely custom tool, often at a cost of tens of thousands of dollars.

The need for custom-fabricated tools and equipment should be figured into the initial bid, and the fabrication timelines should help determine the timelines for work completion. But even when properly planned out, equipment limitations may eliminate the possibility of taking on these jobs.

Coordination

Large-scale repairs take a great deal of coordination and communication to complete, mostly due to where the repairs take place. Whether the pipelines are under multiple city streets and neighborhoods or under airport runways or major roadways, teams encounter disruptions, restrictions, and challenges unique to each location. That makes coordination a necessary component of the planning process.

Teams will need to plan with municipal boards, city councils, and other teams to minimize disruptions. While this coordination takes time and energy ahead of the project, that coordination pays off in smoother, faster work during the project itself.

T3:  Experts in CIPP Repair

So what does all of this mean for smaller CIPP repair companies?

In most cases, these large-scale CIPP repair jobs will be hard to accomplish for the typical small business. Instead, these jobs are better suited for larger companies that have the equipment and crews to complete jobs of this magnitude.

But if you happen to win a larger job for your CIPP repair business, you’ll need to be ready with top-notch equipment, materials, and support. T3 Lining Supply can be the bridge between your regular work and larger jobs like these.

Our highly trained and experienced team works directly with your business to keep you on top of everything you need to be successful with your repairs. We’ve got a wide network of contacts that can help you out when the job is big, and we work directly with respected manufacturers in the CIPP industry to provide high-quality tools and rigorously tested resins.

But even if you’re just not sure where to start with residential sewer pipe repairs, we’re ready to help. Reach out today to see why T3 is the trusted source for pipe lining supplies nationwide!