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Introduction to the UV-CIPP (Ultraviolet Light-Cured In-Place Pipe Repair) Process
Release time:
2016-08-05 15:57
I. Pipeline Repair
Pipeline repair refers to the application of various technologies to restore damaged or leaking pipelines to their normal operational function. Such repairs encompass two main techniques: external anti-corrosion layer restoration and internal repair.
II. Why Pipelines Need Repair
After years of operation, various pipelines inevitably suffer from damage and leaks due to factors such as corrosion and poor operational management, leading to significant economic losses. However, replacing the entire pipeline with new ones would not only involve an enormous amount of work but also be costly and time-consuming. Consequently, how to restore pipeline safety efficiently, economically, and quickly has attracted considerable attention both domestically and internationally. Therefore, research into pipeline repair technologies is of great significance.
III. Pipeline Repair Technologies
Pipeline repair refers to the application of various technologies to restore damaged or leaking pipelines to their normal operational function. Such repairs encompass two main techniques: external corrosion protection restoration and internal repair. External corrosion protection restoration involves inspecting and evaluating the pipeline’s external anti-corrosion coating, followed by repair work based on the assessment report. Internal repair technology is more challenging; a common method is the liner-in-place technique using a flexible hose. In this process, a fiber-reinforced hose coated with an impermeable membrane is thoroughly impregnated with resin and then expanded—either by air pressure or water pressure—to tightly adhere to the inner wall of the existing pipeline. After thermal curing, a smooth, glass-fiber-reinforced plastic liner is formed, thereby completing the repair of the old pipeline.
1. CIPP Inversion Hot-Curing Repair Technology
The inversion method uses air or water to invert a resin-coated liner hose into an existing underground pipeline. This method allows for quick and convenient material delivery. After the hose is heated and cured, it forms a high-strength new lining inside the existing pipe.
2. CIPP Pull-in UV Repair Technology
The ultraviolet light curing method involves pulling a material hose into underground pipelines using a traction process. After being cured by ultraviolet light, the material forms a new liner inside the existing pipeline. This method requires significant tensile force when the material hose is pulled into the pipeline; typically, a geomembrane is first laid in advance within the pipeline before construction begins.
3. Construction Process
(1) Remove the protective film from the liner hose (before inserting the liner hose).
(2) Insert the inner lining hose.
(3) Inflating the inner-liner hose
(4) CCTV monitoring of the UV curing process for lined hoses
4. Comparison of UV and Hot Water Curing Technologies
| UV-curable liner technology | Flip-in Hot Water Curing Liner Technology | |
| Construction method | A fiberglass resin hose is pulled into the pipeline and, after UV curing, forms a new high-strength liner pipe. | The non-woven fiber resin hose is flipped into the pipe, and after curing with hot water, it forms a new high-strength liner pipe. |
| Lining method | Pull-in type | Flip-style |
| Bloating method | Atmospheric pressure | Water pressure |
| Curing method | UV | Hydrothermal curing |
| Applicable pipe diameter | 150-1800mm | |
| On-site | No crane involved, minimal impact. | Crane required. |
| Construction time | 3 hours before and after, UV curing for 1.5 hours—totaling 4–5 hours. | 3 hours before and after, followed by 6-8 hours of curing in hot water, for a total of 9-11 hours. |
| Design thickness | 3-16mm | Generally 9mm |
4. UV-CIPP
UV-CIPP (UV Cured-In-Place Pipe) ultraviolet-cured liner hose is made of light-curable composite materials and is specially designed for the rehabilitation of various drainage pipes, including sewage pipes and stormwater pipes.
1. Scope of Application
(1) Suitable for underground drainage pipes or channels;
(2) The cross-section of the repaired object can be circular, elliptical, egg-shaped, square, or other special shapes;
(3) The inner diameters of applicable circular pipes typically range from DN150 to 1200 mm, with the maximum pipe diameter reaching up to DN2000 mm.
(4) The single repair length (typically) can reach up to 200 m; other lengths must be custom-made.
2. Process Advantages
(1) Minimal impact on traffic and other infrastructure. This is a true 100% trenchless liner repair, eliminating the need to excavate working pits.
(2) The construction is highly controllable and the project duration is short. The installation method involves pulling the pipe into place without requiring inversion, and the entire curing process is monitored by CCTV. On-site curing typically proceeds at an average rate of 1 meter per minute. For each segment of work—excluding time spent on cleaning the pipe walls—the entire pulling-in and curing process can be completed in just 3 to 4 hours.
(3) Energy-efficient and highly safe. Utilizing UV curing, this method requires lower energy consumption. No water or steam is needed for curing at the construction site, and no toxic gases or other harmful substances are produced. This approach is highly beneficial for ensuring the safety of construction workers and nearby residents, as well as for protecting the environment.
(4) The liner pipe features excellent sealing performance, strong corrosion resistance, and a long service life.
(5) Low loss of current-carrying capacity. Compared to lining materials such as felt, SAERTEX-LINER® liner pipes can achieve the same strength as polyester needle-punched felt liners while using thinner wall thicknesses (3 to 12 mm), thereby minimizing the reduction in the pipe’s inner diameter.
(6) It boasts a high flexural modulus as well as superior flexural and tensile strength. Compared to traditional liner hoses made from synthetic fibers such as polyester needle-punched felt, the SAERTEX-LINER® liner material is composed of reinforced glass fiber composites, enabling it to withstand significantly higher loads than conventional liner hoses produced from synthetic fibers.
(7) Has obtained multiple certifications: the “General Building Supervision License” from the German Institute for Building Technology (DIBT), certification under EN13566-4 (European Standard) from the French Centre for Scientific and Technical Research on Building (CSTB), and certification to ASTM F1216-2006 and NSF/ANSI Standard 14 from the United States.
V. UV Light Chain Kit
1. Pipe diameter: DN150–DN600
2. UV lamps: 600W × 8, 400W × 8
3. Cable length: 150m
4. Cameras: 2
5. Temperature sensor: 1 unit
6. Styrene concentration sensor: 1 unit
7. Pressure sensor: 1 unit
8. Curing speed: 0.5–1.5 m/min
9. Wall thickness: 3–12 mm.
10. Sealing heads: 5 pairs
11. Lamp bases: 5 sizes
12. Blower: 9 m³/min
13. Generator: 30 kW
VI. The 13 Steps for Installing Light-Cured Liners
1. Clean the pipeline
2. First inspection: Use a CCTV camera to inspect the condition inside the pipeline to be repaired.
3. Preparation for installation: First, place a protective PE film liner at the bottom of the pipe to prevent damage to the outer membrane.
4. Installing the liner: Through the inspection chamber of the sewer pipe, use a winch or pull the liner hose into the pipe.
5. Seal the end cap and inflate.
6. Release the air and insert the UV lamp chain into the hose.
7. Second inspection: After inflation, use the camera on the UV lamp chain to inspect the liner tube.
8. Turn on the UV lamp to cure the hose.
9. After curing is complete, remove the UV lamp.
10. Third inspection: Inspection of the curing process and documented records, as well as assessment of the curing quality.
11. Fourth quality inspection: Leak detection, followed by sampling a portion of the product for final quality testing.
12. The connection at the very end of the liner pipe is cut open using a cutting robot, and the end of the liner pipe is joined to the existing pipe and pipeline.
Connection Handling
13. Fifth quality inspection: The TV camera enters the inspection and generates a complete report.
7. Characteristics of Glass Fiber Lined Hoses Using Light-Curing (UV) Repair Technology
1. A double-layer structure (sandwich structure) composed of an inner tube and an outer tube.
2. Elastic modulus of the s-liner material: At least 12,000 N/mm².
3. Size: DN150 to DN1500
4. Variable-diameter liner installation can be carried out within a single section.
5. Liner wall thickness: 3mm–16mm
6. Curing method: Ultraviolet light
7. The liner design is based on an ECR fiberglass resin system containing unsaturated polyester resin and vinyl resin.
8. Resin Types Used in CIPP
| Resin type | Feature | Curing method |
| Meta-phenyl polyester | Can be filled with additives to enhance toughness. | Thermally cured or ambient temperature cured |
| Meta-phenyl polyester | No filler, excellent high-temperature mechanical performance. | UV-CIPP |
| Isophthalic/Neopentyl Glycol-based Polyester | High thixotropy, fillable, excellent weather resistance in acidic and organic environments. | Thermally cured or ambient-temperature cured, as well as UV-CIPP |
| Epoxy vinyl resin Bisphenol A epoxy vinyl ester resin |
No filler, good internal lining wetting, corrosion-resistant, temperature-resistant. | Thermosetting or UV-CIPP |
| Vinyl hybridization | Thixotropic, high-temperature resistant, environmentally sensitive piping | Thermally cured or ambient-temperature cured, as well as UV-CIPP |
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