|
Molson Breweries Utilizes No-Dig Technology To Repair Underground Pipes With Zero Downtime And Reduced Costs |
|
Montreal – Molson Breweries, founded in 1786, is one of the largest breweries in the world and owns the oldest beer brand in North America. Their production facilities are expansive and produce at high volume daily. Underneath the industrial plant is a network of cast iron sewer pipes, many decades old and suffering from premature corrosion inherent in the beer-making process.
When these needed repairs recently, shutting the plant down was not a viable option due to production demands. Moreover, repair costs for traditional repairs would have been extensive as the plant floor would have to be dug up. To make matters worse, there were areas where it was simply impossible to dig. To overcome these problems Molson chose a no-dig solution.
In addition to no manufacturing downtime or loss of production, utilizing a no-dig option meant significantly reduced repair costs: no concrete floors to break and replace, no plant machinery to relocate, no cleaning afterwards. After a thorough review Molson’s Maintenance Manager selected FORMADRAIN® No-Dig Technology.
Since 1994 FORMADRAIN has consistently proven itself as an effective option in repairing or replacing laterals (house sewers) or other underground pipes. It has also been used in a variety of applications with great success. The most obvious benefit of the system is that it can be installed without digging a single hole (unlike “trenchless” systems where there is no trench but large access holes at either end of the pipe). The process utilizes a liner with an epoxy formulation that is inserted inside the existing pipe (it’s a pull in place system), but with minimal loss in diameter. Another unique feature of FORMADRAIN is that the new pipe, once installed, is injected with pressurized steam allowing for an incredibly short curing time: 35-45 minutes for Sewer Liner and 2 h for Industrial Liner.
Wide-Ranging Applications
Practically any kind of pipe-related issue can be solved: elbows, transitions from one diameter upsize, laterals, point (spot) repairs and even “Ys” and “Tees”. The ability to line Ys and Tees is especially important in industrial applications where sewer networks typically involve many pipe connections. With FORMADRAIN both “Y” and “Tee” connections can be repaired from existing cleanouts without any digging. The company developed a new “mandrel” (rubber sleeve used in the process) that is small enough and of sufficient flexibility to be inserted into a standard cleanout, while having the ability to expand 200% in diameter, once injected with steam. It must also withstand steam pressure at 20psi.
FORMADRAIN Technology can be used as much as for residential, commercial, municipal and industrial applications with success and there are more than 25 licensed installers of the system across North America. The materials used in the process are of the highest quality and include Fibreglass, Epoxy and polyethylene. The FORMADRAIN Liner is NSF (National Sanitation Foundation) 14 certified. The liner’s mechanical properties (flexion and tension) exceed the minimum standards of ASTM F1216 by five times. This is an important advantage for smaller pipes in that a thinner wall thickness can be used while maintaining substantial strength and longevity.
CATT performed 13,000 hour creep tests on FORMADRAIN from which a value of the long term (50 years) Modulus of Flexural Elasticity of FORMADRAIN Liner was determined. This data is of importance to accurate design of the FORMADRAIN® Liner thickness according to ASTM F 1216.
Steam curing allows for excellent quality control during the installation process, as well as producing a liner with an elevated chemical resistance which would not be possible without a controlled heat source.
Molson Breweries
The Molson project involves a huge underground pipe system located beneath the plant (no photographs were authorized to protect trade secrets). Many pipes exist in areas where it is impossible to dig. The repairs involve lengths of pipe up to 90m (300 feet) with diameters of 150mm (6 inches) and 100mm (4 inches). The badly corroded pipes include eight ‘’Y’’ connections (floor drain and lateral connections) that had to be renewed.
For this project a Novalac Epoxy resin (FORMAPOX 301) was utilized, which was especially designed for industrial purposes. In fact, the FORMAPOX 301 Liner has chemical tolerances that exceed those of breweries. It was used to assure a life expectancy of 50 years.
Prior to installation, the existing pipes needed to be properly prepared (this is as important as the lining itself). This included deep cleaning (with standard and high water pressure equipment) to remove some soft and other very hard residues (concrete).
The project is currently 50% completed [Note: Since this article was written this project has been completed 100% with success] and there has been no loss of production, to Molson’s great satisfaction. It is estimated to be completed in 15 days.
FORMADRAIN is currently completing development of their LMC (Lateral Main Connection) system for municipal applications (this is another version from the existing LMC system). This will allow the repair of “Y’s” and “Tees” without requiring access from inside a house or building. |
|
Pictures of before and after “Y” connections of recent projects: |
|
Molson Breweries recently utilized the FORMADRAIN No-Dig System to renew underground pipes with complete success |
