Completed Projects With Photo Examples
Sewer / Drains
Location
Address: AMP Building
Area: Circular Quay Sydney
AMP Building at Circular Quay Sydney constructed in 1959/60, was undergoing a major $90 million refurbishment. The plumbing contractor for the refurbishment contacted nuflow as he had found no other system of pipe relining in Australia able to carry out the relining on a project of this magnitude.
When nuflow investigated, the site access to the areas to be lined was limited; access to the down pipes was gained from the roof of the AMP Building, after the roof sumps, which had been welded in place, had been removed.
It became clear from the start that any repairs required would need to be thoroughly investigated due in part to the access points, the large number of 45 and 90 degree changes in direction and the fact that tenants were using most floors and could not be disturbed. The length of liners required the works to be carried out in two stages. Stage one would start from the 26th floor and stage two would start from the 13th floor. Stage two requires access panels to be cut into the pipes in order for the liners to be inserted.
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Closed Circuit TV (CCTV) Investigation
The CCTV investigation showed the problem as being all four 150mm galvanized down pipes corroding badly. The leak’s that are current and any future ones are of a serious concern and need immediate repair.
All the pipes will require cleaning by high pressure jet, before installation of any liners can commence |
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Result after Reline -
Approximately 100's of Thousands Saved
Nuflow carried out the following whilst
installing another successful reline.
Excavation: None
Length of liner: 110 Lm per down pipe
Downtime on pipes: 12 hours - set up, curing and clean up time.
Type of liner: Continuous line, 45’s, 90’s and lateral connections
Resin used: Fast |
Alternatives
The savings to reline the down pipes over replacement is substantial and will prove extremely worthwhile in cost, logistics and quality.
This project reveals that you have to plan installations very carefully. Careful and investigative planning resulted in a totally different approach to this job and re-enforced the great belief in thorough research and planning before undertaking or quoting on any work.
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Location
Address: Tugan Bypass
Area: 600mm Storm Water Pipe
During the construction of the Tugun bypass, water monitoring observed an increase in flow of water through the storm water system even during times of minimum rain fall.
Access to view this particular break was gained by physically entering the line via a 15 metre deep, pump out sump 50 metre's up stream of the problem. The timing of access to the line had to be coordinated with the rise and fall of the ocean tides, as the amount of infiltration greatly increased during high tide. Previous attempts to seal the infiltration by using putty and expanding foam have proved unsuccessful due to the water pressure pushing through the gaps. To ensure the reline of this amount of infiltration is successful, it will require a second liner to be installed over the first, doing this will completely seal the problem.
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Closed Circuit TV (CCTV) Investigation
After carrying out the CCTV operations in the pipe we were able to locate the problem as being a major infiltration in a 600mm concrete storm water pipe.
Access to the particular problem was gained through a sump pit in an up stream location of the infiltration. |
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Result after Reline - Saving of approximately millions and a 3 month delay on completion
Nuflow carried out the following whilst
installing another successful reline. Excavation: None
Downtime on pipes: 8 hours - set up, curing and clean up time.
Length of liner: 1 Lm
Type of liner: Patch
Resin used: Slow |
Alternatives
An alternative to the relining of this project would be to excavate the pipe and renew the damaged section; this would have involved having to effectively plug the area off that was to be excavated to reduce or even stop the flow of water, in order for an external repair to be carried out or a new piece of pipe installed.
The downtime on this pipe repair was kept to the minimum by utilising a pump to remove the storm water from the pit up stream of the repair and discharging into the downstream pit, below the repair.
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Location
Address: Hotel Broadway
Area: Woolloongabba
The Hotels toilets were backing up and during extreme use would overflow. This issue was further compounded as the waste from the main bar entered the same sewer line.
Access to the sewer line that required investigation and repair was particularly awkward as it was located in the cellar under the main bar, which was in general use from 9am.
The line itself was attached to the floor joists of the bar; this further compounded the point of access as a hole was required to be cut in the top of the line to allow the investigation and clean to be carried out and the liner to be inserted. An access hole was cut in the line and a plug was inserted up stream in order for the works to be carried out. The pre and post photos show different metres form point of entry as they were taken from the upstream and downstream points of entry, this was due to the reduced access in the main bar.
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Closed Circuit TV (CCTV) Investigation
After carrying out the CCTV investigation in the line we were able to locate the problem as being a displaced joint and a length of root intruded 100mm earthen ware sewer line running from the cellar out into the hotel car park.
This required water jetting, to clear the line, and the installation of 3 meters of liner in order to repair the displaced joint and seal the areas where roots were protruding. |
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Result after Reline - A Saving of $16,000
Nuflow carried out the following whilst
installing another successful reline.
Excavation: None
Length of liner: 3 Lm
Downtime on pipes: 4 hours - set up, curing and clean up time.
Type of liner: Continuous line
Resin used: Fast
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Alternatives
An alternative to the relining of this project would have been to excavate the area and replace the pipe. This would have involved closing the front doors of the hotel for the duration of the repair works, dismantling a large section of the wooden deck at the front of the hotel, excavating a trench from the hotel out into the car park and extracting the existing line from the cellar wall. All of these works would have caused a major disruption to the day to day operations of the hotel and inconvenience to its patrons as it would have in effect closed all the frontage of the hotel.
The only inconvenience caused to the hotel during the relining works was limiting the number of amenities that were used during the downtime, whilst its patrons could still enjoy a beverage on the front deck.
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Location
Address: Milan
Area: Gold Coast
Soaring high above Main Beach, Milan rises 19 levels to offer sweeping panoramic views of the Gold Coast. Completed in Mid 2008, Milan offers exclusive holiday / permanent residence living with its one unit per floor apartments.
Extensive resort like facilities including, 24 hr concierge service, heated lagoon and lap pools, ensure a relaxed holiday and residential environment is enjoyed.
The operational maintenance manager of Milan contacted Nuflow as the ‘relaxed environment’ was being disturbed by leaking 50mm pipes that fed the lagoon pool, and the hot tub.
Nuflow visited the site to carry out a CCTV inspection of the leaking pipes. We encountered extremely limited access to the pipes as they were located in an underground rain water holding tank, which needed to be partially emptied so that the pipes could be exposed and disconnected. The next major issue; there was no down stream access due to the complexity of the pipe lay out from the pool and hot tub. This restricted our methods of installing the liner to a process unique to Nuflow.
On the day of the works to proceed, the tank was once again partially emptied, upon which an installation team member, wearing a wet suit, entered the tank. The single access liners had been specially made and tested the day before, and after being ‘wet out’ they were passed into the tank and inserted.
Alternatives
The alternative solution of excavating and replacing the pipes, was never an option due to the location, disruption, timing and costs involved. Nuflow installed the liners in the morning and pulled them out by mid afternoon the same day. Having minimum impact on the use of the pool and hot tub.
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Location
Address: Jezzine Barraks
Area: Townsville
Jezzine Barracks has been used for defence purposes since the late 1800’s. The historic site was identified to be sold off by the Department of Defence, the strong community reaction to this prompted the Department of Defence along with the Commonwealth and State Governments to commit to a $40 million dollar redevelopment plan.
From the date of the initial enquiry, the urgency to complete these works was made very clear to us, all the site works had been proceeding smoothly and on time until it was discovered that major infiltration and exfiltration was happening in all of the underground sewer lines. Once the problem had been reported a quick solution was sought as it had the capacity to stop all other works from being completed. Nu Flow’s response to this was to quickly send a specialised team with all materials that could possibly be required up to the site for an immediate start, from the day of the initial enquiry to the team arriving on site was 3 days.
Upon completion of the CCTV inspection it was confirmed that all the lines would require relining. In all, 70 metres of 150mm and 60 metres of 100mm earthenware pipe; along with 5 metres of 100mm copper pipe required relining. The 3 man installation crew completed the entire project from the initial CCTV inspection to the final inspection in 4 days, this was achieved by working longer hours to ensure as many liners were made and installed each day as possible.
Being an historic site and defence museum meant that extreme care was required so as not disturb any of the property above ground and minimise any damage to the sewer lines due to their historical significance.
Result After Reline |
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Dig & Replace |
Nuflow |
Installation Time |
Weeks |
4 Days |
Disruption |
Access to buildings and site in general |
Not Effected |
Safety |
Electricity, water, Phone lines, open trenches. |
Not effected, epoxy resins safe and have no odor |
Environmental |
Dust from concrete cuts, noise, waste |
Neat, clean no mess |
Property |
Loss of historical artifacts |
No disturbance |
Restoration Costs |
Thousands |
No cost |
Alternatives
Due to its historical significance the alternative action of excavating and replacing the damaged pipes was not a consideration. This would have caused lengthy delays as it could have involved archaeological monitoring of any disturbed area of ground and due to the location of the pipes in the old toilet and shower blocks the floor surfaces would have had to be removed.
This project reveals that Nu Flow can work closely with customers on projects with a sensitive nature. In this instance an historic site will remain undisturbed but its infrastructure will continue to work efficiently for many years to come.
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Location
Address: Mingaletta St
Area: GCCC Ashmore
The road above the line was constantly being patched after heavy rain. After one particular storm the road collapsed resulting in a thorough investigation of the storm water line being carried out.
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Closed Circuit TV (CCTV) Investigation
After viewing the CCTV footage supplied by the client it became very apparent that a section of 300mm concrete stormwater line had become seriously broken and had numerous areas of root intrusion.
The line will require water jetting to clear the blockage and installation of 15 m of liner to cover the broken section and the areas of root intrusion. |
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Result after Reline
Nuflow carried out the following whilst installing another successful reline.
Excavation: None
Length of liner: 15 Metres
Downtime on pipes: 10 hrs - set up, curing and clean up time.
Type of liner: Continuous liner, in sections
Resin used: Fast
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Alternatives
An alternative to the relining of this project would be to excavate the area containing the broken section and repairing in the conventional way. This would have resulted in the need to close a section of the road, for the duration of the repair causing traffic congestion and inconvenience. To add to this, additional infrastructure services may have been required at the time of the repair due to an electrical mains and communication conduit being visible from the hole in the line.
Using the nuflow relining method to carry out this repair ensured that any inconvenience was kept to a minimum, and that the root intruded areas were sealed rather than just repairing the broken section.
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Location
Address: Lanercost St
Area: Geebung
All of the utilities linked to the sewer line were having difficulty clearing and during times of high use, the drains would back up.
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Closed Circuit TV (CCTV) Investigation
All of the utilities linked to the sewer line were having difficultAfter carrying out the CCTV investigation in the pipe we were able to locate the problem as being an extended length of root intruded and displaced 100mm earthen ware sewer line running from an I.O at the side of the house out to the council main at the front of the property.
This will require water jetting to clear the line and installation of 23 meters of liner in order to repair the displaced area and seal the joints where roots are pushing through clearing and during times of high use, the drains would back up. |
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Result after Reline
Nuflow carried out the following whilst installing another successful reline.
Excavation: None
Length of liner: 23 Lm
Downtime on pipes: 24 hours - set up, curing and clean up time.
Type of liner: Continuous line, in sections
Resin used: Normal |
Alternatives
An alternative to the relining of this project would have been to carry out an annual inspection and clean of the problem areas; or to excavate and replace the root intruded areas of pipe.
Annual maintenance would have incurred an annual cost that would not have solved the problem of the roots and the displaced joint would have continued to deteriorate.
The excavating option would have involved cutting and digging through concrete paths and established gardens. All of which would have produced a degree of waste and inconvenience.
The only inconvenience caused to the household during the relining works was limiting the use of amenities that could be used during the repair time.
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Blowable
Aircraft Hangar at Fort Drum The 10th Mountain Division
A military aircraft hangar at the Fort Drum 10th Mountain Division was the site of another ‘coup de gras’ for Nu Flow. A team of potable lining specialists lead by Dennis Fort successfully epoxy coated an AFFF Fire Suppression System using the patented APL 2000 epoxy.
The plumbing system perched above several military helicopters, suspended 50 feet high in the hangar’s rafters. The crew spent most of the job working from a platform suspended over the birds by crane.
In total, the team lined the Fire Suppression Deluge system and the 100% AFFF Distribution System, consisting of 420 open sprinkler heads on six deluge systems. Pipe diameters ranged in size from one to six inches. More than 5,800 feet of pipe was lined over an eight week period. The Nu Flow team was supported by contractor Mandaree Enterprises, as well as the U.S. Army throughout the process. Over 5,800 feet of pipe was lined with epoxy coating.
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Heathgate Condominiums
10 Tichester Road is part of the Heathgate Community, a well established and distinctive condominium complex, located in the exclusive Forest Hill area of Toronto. Built in 1989, this luxurious 60-unit building has an average unit value of $700,000. The community boasts excellent facilities, including recreation rooms, an exercise equipment room, and an indoor and outdoor pool. Inside its picture perfect façade, the 18-year-old copper piping system leaked throughout the structure. Mandatory chemical additives to treat drinking water had slowly eroded the pipes, resulting in multiple, active pinhole leaks.
With leaks in horizontal branches, vertical runs, and risers, the plumbing system sprung roughly one new pinhole leak each week. The owner was spending up to $60,000 per year in pinhole leak repairs, and needed to find a more affordable, permanent solution to the problem. Percel property managers began researching alternative repair options.
Research results indicated a repipe would take up to four months to complete. Accessing the deteriorated pipe would require tearing into walls and internal facades throughout the property. The noise, mess, and down time would require the displacement of residents, many of them in their 70’s, while the work was performed. After the repipe, reconstruction of the damaged access points would mean longer down time, more mess, and as much as 40 to 60 percent additional cost for the structure’s restoration.
Percel President Robert Weinburg, then contacted NuFlow to find out about in-place pipe restoration. Weinburg learned that the lining process uses a thin epoxy coating, which is “shot” through the pipes, creating a barrier coating between the piping system and corrosive water, which permanently prevents pinhole leaks. The process leaves walls intact, eliminating displacement of residents, and takes considerably less time than repiping, and usually at less than half the cost.
The decision was made to use Nu Flow, and the job began in January, 2008. All potable water plumbing on the property including hot and cold recirculation lines, the mains, and all pool lines, were lined successfully and on schedule.
A job of this scope requires clear communication and excellent on-site customer relations, a critical factor when elderly residents are involved. Nu Flow took tenant relations very seriously, using a regularly-updated job board in the main lobby, individual notices, phone calls, and personal contact to ensure residents were aware of the job parameters and how the work would affect them.
The entire project was completed in three months and the property managers at Percel were very pleased with the completed work and the manner in which it was performed.
There was no displacement of residents at the 60-unit building during the pipe relining process.
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Nu Flow Completes Rehab of Fire Training Center
Nu Flow’s Potable Lining Specialty Team arrived at the San Diego Naval Base Fire Training Center in May of 2008 to execute a special mission. Several buildings at the facility had experienced multiple plumbing leaks. Repiping was considered and was rejected due to exorbitant costs and lengthy down time. Epoxy pipe lining was selected as the weapon of choice to attack this problem.
Engineering Support Personnel (ESP) was the primary contractor for Naval Center restoration and it subcontracted NuFlow to complete the task based on Nu Flow’s extensive resume and excellent reputation. Nu Flow’s marching orders included rehabilitation of six buildings containing more than 2,900 feet of potable water lines, black steel pipe, ranging from 1 1/2 to 6 inches in diameter.
Nu Flow team leader Matt Marcum met with ESP supervisor Mike Oliver to coordinate the project by stages and formulate a work schedule that would promote clear lines of communication between the Nu Flow team and naval base personnel.
“Communication and flexible scheduling are the key to happy clients” says Marcum. “A job of this size requires as much customer service as epoxy application.”
Potable water system rehabilitation consists of three primary steps: preparation, cleaning, and lining. To properly prepare, all of the pipe runs, connections and valves are indentified. Next, all valves are removed and air hoses are attached to all of the fixtures. Compressed air and particulate is then used to clean the inside of the entire piping system. Finally, when the system has been dried, a certified-safe epoxy is “blown” through the pipes, distributing an even epoxy coating inside the pipe.
The direction of epoxy coating is controlled by a master header that adjusts the level of compressed air flowing to various fixtures. The end result is a smooth, even epoxy barrier between the pipes and water that stops leaks and prevents heavy metals from leaching into copper pipe, and prevents calcium build-up due to corrosion in galvanized pipe. The project began with the three smallest fire training biuldings, each of which contained approximately 300 feet of pipe.
Stage two consisted of two larger buildings, each containing 500 feet of pipe. The final stage included the largest of the buildings containing 1,000 feet of pipe, as well as some unique challenges.
The project was completed on time without incident. Oliver reported that the Navy was very happy with the work performed and is interested in using the Nu Flow process in future Navy projects. Nu Flow is in the process of arranging an on-site demonstration for additional EPS and naval staff.
The center trains more than 35,000 military personnel each year, and is also used for training local firefighters and civilians.
Nu Flow is a proud supporter of our U.S. military.
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Plymouth Harbor
Pipe lining technicians for the Nu Flow Companies began water pipe and drain line restoration of the luxury retirement community of Plymouth Harbor on Sarasota Bay in Florida in July of 2007. The multi-million dollar contract is the largest combined technology project ever awarded in the small diameter pipe lining industry. The contract signifies a growing trend in the use of epoxy pipe lining to address deteriorating water infrastructure globally. Established in 1966, Plymouth Harbor on Sarasota Bay is a non profit, 25 story, multi structure complex with full amenities and services, including its own skilled nursing facility. Home to judges, a Nobel Prize recipient, artists, clergy, academicians and CEOs of U.S. and international corporations, the community is distinguished by itsinnovative architectural design and the world-class services enjoyed by its mostly senior residents.
Perched on 16 stunning acres of Florida coastline, Plymouth Harbor’s facilities are first class, and they take a proactive stance in maintaining the property and residents’ comfort. When plumbing issues arose, the board’s primary concern was minimizing disruption to residents, so the time, cost, and destruction of traditional repiping were simply not feasible.
“We began investigating epoxy lining companies in the summer of 2006,” said Harry Hobson, President and CEO of Plymouth Harbor. “Nu Flow was awarded the contract in April, 2007 based on their experience and reputation, and the fact that they were the only company capable of providing both drain and potable pipe lining.”
Key points of the job include, the main tower, a 25-story building, three additional three-story structures, chiller mains that are 12 inches in diameter, potable water mains that are four inches in diameter, and a fully functioning medical wing that offers a variety of challenges and opportunities.
“The Nu Flow team has been very professional, has demonstrated an excellent work ethic, and has maintained great communication with residents and staff. During the course of the project, they’ve scored high marks in all categories. We couldn’t be more pleased that we chose Nu Flow to address this important capital improvement project,” says Hobson.
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The San Diego Naval Base Fire Training Center
Location: San Diego, CA Work
Performed: Nu Flow rehabilitated more than 2,900’ of black steel pipe, from 1-1/2 to 6 inches in diameter.
Displacement of Occupants: Minimal
Installer: NuFlow Epoxy Coatings Division
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Met Life Building 60 Stories
Location: Downtown Manhattan, New York, USA
Work Performed: 150mm and 200mm galvanised water mains were rehabilitated using the Nuflow in-place pipe restoration method
Displacement of Occupants: Minimal
Installer: Nuflow Atlanta, USA
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US Navy
Facility description: Aircraft carrier vessel
Work performed: Restore copper/nickel waste and discharge piping
Project duration: 3 weeks
Pipe size: 100mm, 125mm and 150mm diameter
Disruption/displacement of facility occupants: None
Actual cost of Nuflow Pipe Lining method: $308,000.00
Estimated cost of traditional pipe replacement: $2,400,000.00
Cost savings achieved: $2,092,000.00 (87%)
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