Pipe relining origins   

Just like any successful business in today’s world – innovation is a non-negotiable. Over the last couple of decades, breakthroughs in the science and engineering fields have resulted in advanced and environmentally-friendly pipe repair technologies that Nuflow is now renowned for. This technology has made it possible for broken pipes to be repaired from the inside, eliminating the need to dig up and completely replace the affected pipes.  

Nuflow’s pipe relining methods 

Pipe relining, or “trenchless repairs”, involves old pipes being left in place while new pipes made from tough, durable composite resin materials are formed inside or around the existing pipes. Mitigating the need to excavate, dig or destroy, trenchless repair strategies like cured-in-place pipe (CIPP) relining means more cost-effective and convenient solutions for broken pipes, resulting in significantly less environmental impacts.  

The CIPP relining process

CIPP relining is one of the most popular ways to repair or rehabilitate pipes without digging and replacing. Essentially, advanced composite resin materials are inserted into failing pipes to repair damage, improve flow and extend the life of the pipe. For pipes that need structural strength (i.e. beneath roads or driveways), a liner infused with the resin is pulled into place before being cured into a cement-like structure.  

For non-structural pipes like water pipes in ceilings or walls, the resin is blown into the pipe to cure, forming a new pipe lining that will keep it strong and functioning well for years.  

These structural and non-structural relining methods are suitable for pipes carrying drinking water, waste and storm water, chemical (trade) applications, and grain, feed or sludge (industrial) applications.

At Nuflow, we understand that not all pipes are the same, which is why our pipe relining methods are tailored to suit each unique repair. We take into consideration the type of pipe, the climate, other environmental conditions, the operational needs of the client, and the built structures or services in the immediate area.

We use CCTV camera equipment to locate the problem area and where future pipe repair problems are likely to occur, providing you with a full discovery of the state of your pipes. We then use a variety of methods like water jetting and specialised plumbing tools to ensure your pipe is cleared and cleaned quickly and safely. Once your pipes are prepped, they’re ready to be relined with one of our four relining solutions:

Blueline^®     

Our structural solution suited to non-pressure drainage applications like stormwater pipes, sewer pipes, trade waste pipes, and more. It’s super versatile, and allows for sectional relining of any pipe length. Learn more.

Ultraline^®     

Our latest offering is a strong and lightweight fibreglass liner with an epoxy resin that is cured by an ultraviolet light train. The result is faster fixes and less time on site. We are currently using this technology for short patches on pipes of up to 150mm diameter, but we hope to be doing much larger projects soon.

Greenline^®       

This is also a structural pipe restoration solution. It’s used for high pressure main pipes, asbestos cement, UPVC, copper pipes, steel pipes and potable water pipes. It complies to international standards for drinking water, with the ability to withstand long term pressure of up to 1800kpa. Learn more.

Sumoline^®  

Our strongest CIIP relining system. It’s used on non-pressurised, built infrastructure with critical load bearing capacity, like bore storm water and sewer pipes, road and rail infrastructure, box culverts, and manholes. It can cure underwater, and will not shrink. Learn more.

The benefits of pipe relining vs replacing

From fixing leaks and preventing tree root intrusion, to stopping lead and other contaminates from leaching into water systems – the list of benefits goes on.

Pipe relining has a number of great structural and functional advantages. It’s suitable for situations where pipes have junctions, bends and transitions in diameter, while also possessing a number of convenience and environmental benefits. This includes eliminating the need for excavation or destruction that can cause damages, saving you a lot of time and money as well as saving the surrounding environment from disruption.

Most impressively, the pipe relining process leaves behind a final pipe that independent tests have shown has a greater strength and flow rate than the original pipe, and any other materials that might have been used to replace it.     

Why you can rely on Nuflow relining 

We back our technology and our installers – that’s why our Nuflow relining products come with warranties of up to 50 years*. This tried and tested solution can be the difference between waiting weeks for your pipes to be fixed, versus mere days. So, if you’re looking for an efficient, cost effective and environmentally friendly alternative to completely replacing your pipes, you know who to call.

Click here for more information on Nuflow’s pipe relining solutions or get in touch with your local team today.

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So, when Dane from Nuflow Blacktown was contacted by their client Flexco about a potential large-scale issue with a twin pipe fire service feed to their building, he didn’t delay in sending a crew to investigate.

When the team got to site, they found that the water supply had been turned off. They reinstated the water supply to ensure the vital firefighting capability was online should there be an emergency.

The following week, to Dane’s surprise, he got another call to advise the water was off again. It was time to do some homework. Dane spoke with the Sydney water area managers, who advised him of a massive leak in the drain under the road.

THE PROBLEM: LEAK UNDER ROAD NEEDED FIXING WITHOUT SHUTTING DOWN THE ROAD

Flexco has a large-scale facility where they manufacture conveyer belts for the mining industry. When both of their dual private water mains broke, they needed it fixed fast. Without the water main crossing up and running, their site didn’t have any fire protection, which meant they had to stop manufacturing and production.

The factory is located across the road from Hillsong Church, where it’s not unusual for over 16,000 people to visit over a weekend. And during the week, the roads around the site are just as busy. Because of this, the local Hills Council could not give permission to open the road to investigate or repair the leak.

So, what do you do if you can’t repair a pipe leak by digging up the pipe? Situations like this are where pipe relining solutions come into their own.  

THE SOLUTION: PRESSURISED PIPE RELINING WITH NUFLOW’S GREENLINE SYSTEM

Dane and Josh from Nuflow Blacktown got busy and decided on a plan with the facility managers from Flexco.

They decided to use Nuflow’s Greenline system to install a structural pipe reline inside the DN150mm copper pipe. Not only would this solve the issue of the leaking pipe, but it would future-proof the pipe against the increased load from the road above, which had seen road traffic increased tenfold over the last decade. 

Greenline is a structural relining system that is capable of rehabilitating potable water pipes from DN40mm to DN1m. The system meets international standards and has AS-NZS 4020 approval and no BPA, so water passing over the reline is fit for human consumption.

The team excavated the end of the pipe inside the Flexco site and inspected using CCTV. They found the damaged pipe, and after getting approval opened the path on the opposite side of the road to allow them to access and reline the entire system.

Dane decided the best approach was to do the reline during the evening. The cooled weather gave the team a longer window to do the necessary work and it allowed for the longer run of pipe to be rehabilitated.

All the site and pipe preparation was completed in advance of the reline taking place. The team ensured the pipe was clean and the damage was repaired. Then, on a cold Sydney Winter evening the crew conducted a clinically excellent reline on the pipe. They used vacuum impregnation technology, coupled with a calibration system that ensured the correct amount of resin was spread across every lineal meter of the multi-layered hybrid liner.

When the pipe liner was pulled into place, the bladder inside it was inflated to allow the resin to bond to the existing pipe. Then, once the pipe had cured, the bladder was removed and the pipe was inspected with a drain camera and recommissioned.

PIPE REPAIR SORTED WITH NO ROAD CLOSURES

This was a challenging job from start to finish, but the crew from Nuflow Blacktown ensured the job was professionally completed with minimal disruption to the busy Norwest Business Park. The road didn’t need to be excavated to expose the damaged pipe, which allowed access to local businesses and met the local council requirements.

To learn more about Nuflow’s patented hybrid relining system and commercial plumbing solutions, talk to your local Nuflow pipe relining experts.  

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So how do you resolve the issue of pipes that are either buried very deep, under busy roads, inside a concrete structure, or simply not able to be dug up without disturbing occupants, or for health and safety issues?

THE PROBLEM: INLET PIPE WAS BURIED IN THE ENGINEERED CONCRETE STRUCTURE

In the ACT a clever solution was needed when it came to extending the operational life of a vital piece of infrastructure.

The local water authority was undertaking a renovation of a 60-year-old water reservoir. But, they needed a solution for the large diameter inlet pipe (DN750mm) that was buried deep within the engineered concrete structure.

It wasn’t possible to replace it without destroying an important structural part of the building or potentially delaying the entire renovation for months.

The reservoir supplied water to homes, schools and businesses in the surrounding suburbs, as well as acting as a balancing tank when water was supplied from a nearby water treatment plant. As such, the solution needed to ensure that the reservoir could continue to provide drinking water to the local community safely, and to the high water quality standard required.

THE SOLUTION: PIPE RELINING WITH NUFLOW’S GREENLINE

Nuflow rehabilitated the pipe using our custom Nuflow Greenline Potable Water relining system. This smart solution utilises the Australian engineered Cured In Place Pipe (CIPP) system for rehabilitation of pressurised pipelines.

Nuflow Greenline consists of a custom manufactured liner that is impregnated with epoxy resin that is free of BPA’s and safe for drinking, and often used for large scale commercial plumbing projects. The liner is pulled into place with a bladder that is inflated, forcing the liner against the 750mm diameter concrete pipe. Once cured, the bladder is removed and a new pipe is now operational within the original pipe.

SMALL FOOTPRINT MEANT EFFICIENT ROLL OUT

This fix was far from straightforward. To access the pipe required entry via a confined space entry conditions pit which was approximately 3.5m deep.

Downstream there was a scaffold platform level, with the outlet of the pipe approximately 7 metres above the reservoir floor.

This was a delicate operation which required attention to be paid to even the smallest of details to ensure the safety of everyone on site. Any accidents could close the site and put this vital project behind schedule, which would in turn impact the local water supply.

A large part of the project involved cleaning and preparing the pipe for relining using high pressure water jets. Following the descaling of the inside of the pipe, we built a custom CIPP liner to the exact specifications of the pipe. This process took place on the scaffold platform, resulting in minimal site footprint and allowing other trades to continue to complete their work during the installation.

The installation of the CIPP liner was completed in 3 days including travel, site inductions and establishment, pipe and material preparation, and cold weather condition curing time. But, this was not the end of the project.

Nuflow Smooth Trowel, a specialised Nuflow manufactured product made with Croc Mate, was used on the upstream and downstream ends of the pipe – providing extra strength against water penetration, and assisting with extending the life of the concrete around the inlet to the pipe.

The project was finished on time, and to budget. The client was thrilled with the results delivered by the Nuflow Wollongong crew. They maintained an impeccably clean site and followed direction and safety protocol to the letter.

Nuflow has rehabilitated many pipes across Australia and New Zealand, from Super Yachts to sewers, and even award-winning historic building restorations. We can reline virtually any size, shape or material of pipe.

As the only local manufacturer of pipe relining solutions in Australia and New Zealand, we should be the first people you speak to about your pipe repairs.

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Nuflow’s successful pipe repair work to a fire protection system at a local shopping centre was recently published in The Cairns Post.

The large-scale job at Lendlease’s Cairns Central Shopping Centre involved relining more than 2500m of pipe for a fire hydrant upgrade and rehabilitation of its fire hydrant mains system.

The post Upgrade to Fire Protection System Big Success At Cairns Central Shopping Centre appeared first on Nuflow.

In this article we will explain the difference between some of the leading CIPP relining products available in Australia today, namely:

• Blueline technology
• Greenline pipe relining
• Redline technology.

Choosing the pipe relining alternative that’s right for you

Decisions, decisions, decisions!! There you were, settling in for an afternoon in front of the footy when the kids run up the hall screaming the toilet bowl’s full to the brim. You jump onto Google for some help, but after looking over the first six or seven sites your head’s beginning to spin.

Pipe relining, drain clearing and plumbing are fairly competitive industries. That’s why an internet search on things like how to fix broken sewer pipes will throw up a long, confusing list of subjective commentary. Most of this advice is generated by those operating commercially in the trade, which makes singling out balanced and genuinely useful information a challenge.

Understandably, most throw their support behind the methods and products their own company offers and ignore or (even worse) denigrate other alternatives. But thankfully there are also some which provide useful and reasonably factual information for those wondering which pipe relining alternative is best for them.

Ways of repairing pipes

When it comes to repairing pipes the first consideration is whether you want:

• a ‘trenchless’ repair (no excavation or digging), or
• an excavation (traditional methods involving digging).

This will obviously depend on your site, your budget and the value of any built structures or landscaping near the site of the break. In open, easily accessible, soft soil where the cause (and extent) of pipe damage is certain, excavation may be the better option (particularly if you are willing to do some of the digging yourself).

If you do decide on excavation and replacement of pipes, your local plumber may be the best person for the job. If it’s a really simple fix, you might even want to try tackling the job on your own. This is not permitted in relation to many wastes and plumbing systems however because of health risks to yourself as well as the general community.

If the exact location, extent and cause of damage are not certain or there are other considerations like site stability, the need for concrete cutting, demolition, or a preference for not disturbing gardens or lifestyle, a trenchless method of repair would be more suitable. For more detailed information on this, we’ve provided a related article explaining the benefits of trenchless pipe repairs.

But that’s nowhere near the end of the ball game. From here you have to decide on the type of trenchless repair that will work best for you, and even then, which method of installation and which specific relining product will do the job.

TRENCHLESS PIPE REPAIRS

There are three main ways of addressing damaged or degraded pipes without the need to dig a trench. They are:

• PIPE RELINING
• PIPE BURSTING
• PIPE RAMMING

Pipe bursting and pipe ramming are more commonly used in major infrastructure projects where there are very big budgets and the capacity to use specialised, heavy machinery. With pipe bursting the old, damaged pipe is basically shattered with a drilling head. The head also drags a new pipe along behind it to be situated in the cavity the shattered pipe once occupied. The remnants of the old pipe usually remain in the soil. There are difficulties, however, if there are joins and junctions which have to be connected, or if there are significant transitions (changes) in the old pipeline’s original diameter.

Pipe ramming also involves the insertion of a new pipe, however, it is usually rammed into the soil alongside or above the existing pipe. The old pipe is disconnected but remains in place, whilst the new pipe takes over service delivery.

Neither of these options actually rehabilitates the damaged pipe and both are costly, meaning pipe relining is the most commonly used method in most situations.

PIPE RELINING

And you guessed it, even once we’ve whittled things down to just relining, there are a few more choices still to make. Essentially, pipe relining involves creating or inserting a brand new pipe within an old, damaged one where it sits in the ground. There is usually no excavation involved at all. This means lower overall cost, faster repairs and no destruction or reinstatement costs for buildings, floors, walls, driveways, gardens or other assets or services located above or near the damaged pipe. Believe it or not, there are four ways this can be done:

• Cured in place pipe (CIPP) relining using composite resins to coat the damaged areas of pipe
• Slip lining where a new, smaller pipe is inserted into the old one
• Fold-and-form lining where a liner is folded and inserted into a pipe before heat is used to re-form it to fit the shape of the old pipe
• Spiral wound lining where a new pipe is mechanically wound into an old one.

Again, slip lining, fold-and-form lining and spiral wound lining methods are most commonly used in major development constructions, while the CIPP method is more popular with domestic and smaller commercial or municipal pipe repair projects.

CURED IN PLACE (CIPP) PIPE RELINING

The cured in place method (CIPP) uses advanced composite resins to seal over damaged areas of the pipe. But just like the box of steak knives being sold on the morning chat show, just wait”¦ there are a few more decisions still to be made.

Essentially, there are three methods of CIPP installation:

• Pull in place where a synthetic liner soaked in a two-part epoxy resin is pulled into place over the damaged area of pipe using ropes fed through existing access points. The liner is then cured to form a rock hard new pipe inside the old.
• Inversion where a synthetic liner (again soaked in resin) is essentially blown (inverted) into the pipe to form a new lining.
• Spray lining (pipe coating).

For non-structural pipes (like fire sprinkler systems) the resin compound will be sprayed into the pipe to coat the interior (spray lining). But if a structural repair is needed (i.e., in sewer pipes under buildings etc.) a synthetic liner will be impregnated with the resin and cured to set rock hard over the damaged areas of pipe (pull in place or inversion methods).

Both the inversion and the pull-in-place methods use this resin-soaked liner concept, but the methods differ in the way the sleeve is placed within the pipe and work best in different situations. The inversion method can be very quick and cost-effective over very long, continuous runs of pipe without bends, transitions in pipe diameter or junctions. It has a heavier footprint, however, requiring machinery to generate energy to invert the sleeve.

Over smaller areas of damage (up to about 50 metres in length) the pull in-place method is usually preferred. This method can also accommodate areas of pipe where there are junctions, joins, bends, transitions and pipes made of different materials because liners can be custom made to suit the configuration of the original pipe.

Pull in place cipp relining for plumbing pipes

So for most residential or small commercial trenchless pipe repair and rehabilitation projects, the CIPP pull-in-place method is the preferred option. With this method, the new pipe (once cured) is even stronger than the original. And because it is joint-less, it is resistant to future invasion by tree roots and able to withstand heavy loads.

There are various types of resins available today, some of which are capable of lining pipes used for drinking water, high impact materials (rubbish chutes), trade waste and high-temperature chemicals. There are also resins that cure underwater, and others designed to line heavy load-bearing pipes (under bridges etc.).

Choosing the right cipp relining product for you

Finally, we come to the choice of the actual relining product. Nuflow is the only fully Australian-owned pipe relining company. They have in-house chemists and engineers who design a range of resins to suit different New Zealand and Australasian conditions. This means the products are locally designed, manufactured, delivered and installed; all of which makes for faster, more efficient and hassle-free pipelining.

Some of the most popular products are their Blueline technology, the Greenline range and a Redline relining product.

Blueline technology

BLUELINE is Nuflow’s structural relining solution for drainage, sewage and stormwater systems, oil, marine and pool pipes and high wear or impact systems. The staple fibre blend of polyester and/or polypropylene in the liner has inbuilt flexibility and high elongation properties that allow engineers to specify mechanical and hydraulic criteria to minimise installation damage and suit a range of tough Australian conditions. The liner is pulled into place using existing access points and quick-cured using an abrasion and impact-resistant, two-part epoxy resin.

This means projects can be completed quickly, safely and economically with minimal disruption to operations, users or the environment. Coming with a product warranty of up to 50 years, relined pipes have significantly increased structural integrity and higher crush and burst strengths than AC and UPVC pipes. This makes them resistant to future invasion by tree roots, corrosion or other processes of degradation.

Greenline pipe relining

GREENLINE is also a structural relining solution but it can be used for high-pressure and potable (drinking) water pipes. It’s the most versatile potable-approved lining system in the world and has excellent curing capacities. This again means that pipe function is restored more quickly and projects are completed efficiently, safely and economically with minimal disruption to access, operations or the environment. Made from a new generation of nonwoven, staple fibre geotextiles and cured in place using a hybrid epoxy resin (safe for use in drinking-water applications) Greenline also comes with up to 50 years’ product warranty.

Redline technology

REDLINE is Nuflow’s non-structural epoxy resin relining solution for pressurised metal pipe networks such as those in fire suppressant or drinking water systems. It can be installed without disruption to walls or buildings and prevents contaminants and micro-organisms (lead, legionella, etc.) from leaching into pipe water. The resin is blown into place using existing access points and cured within the pipe. It takes a fraction of the time it would take to replace pipes, making it an economical and efficient alternative. REDLINE is an epoxy resin lining that protects, restores and extends the operating life of pipes and prevents wear on metal surfaces such as chutes, flanges, elbows and launders. It is suitable for hot and cold potable water, greywater, compressed air, HVAC and fire suppression systems and conduit piping, and it can withstand the psi pressure of the host pipe. The Redline technology has excellent curing capacity, meaning little disruption to users, operations or the surrounding environment.

Nuflow also has products that can cure underwater (meaning services do not need to be disconnected during repairs) and a Sumoline range which has extra strength for applications under bridges, in culverts and for manholes.

If you’d like advice on which relining product is best for you, you can contact a team member here.

The post Which Pipe Relining is Best For Your Pipes? appeared first on Nuflow.

Paul reported back to us,

“Because the trade show targets a niche industry we had the chance to discuss our technique and products at length and in great detail with attendees.We made some great connections this way.

Something we found interesting was that the consensus among exhibiters – that it was vitally important to be at this expo and be visible among our industry peers, particularly for companies that have a very specific and technical offering.

It was such a fantastic chance for us to really demonstrate how our pipe relining products work and to really highlight the benefits of Nuflow within the context of industry-leading products and services.

There was a great deal of interest in our relining techniques for pipe rehabilitation within heritage listed buildings, for example. We also answered a lot of questions relating to our products and how they hold up to high pressure and temperature specifications.

Our potable water solution, Greenline, was a highlight. Greenline can rehabilitate pipes from 40mm 1000mm and is AS/NZ 4020:2005 approved which means it is safe for drinking water as well as being able to withstand pressure up to 1800 kpa.

The fact that our solution enables projects to be completed quickly, safely and economically with minimal disruption to user access and operations, the surrounding environment or resident lifestyle was appealing to the water authorities.

We also received a lot of positive feedback around the fact that we have our own in-house research and development team. Having the ability to custom design relining solutions for difficult pipe rehabilitation projects sets Nuflow apart from other relining companies who do not manufacture locally.”

Paul and Lawrence were joined by two of our franchise partners, Jay Stuart (Nuflow South West) and Jason Lynd (Drainline) who were able to offer a hands-on perspective and discuss some of their case studies. The guys were able to relay their own case studies relating to pipe rehabilitation using our Blueline and Redline products as well as answer questions about installation. Again, water authorities were appreciative of how Nuflow is able to carry out large-scale water pipe repair projects without disruption to the environment and the flow of operations – as in this case study in which a 1200mm steel stormwater pipe located three metres under a main road was repaired quickly, without shutting down traffic and with no disturbance to local flora and fauna.

The team also answered questions about the business from plumbers. While franchise and partnering opportunities weren’t a focus of the exhibition, our franchise model was of great interest to plumbers who visited the stand and the team was happy to continue these conversations.

Overall, Ozwater ’19 was very worthwhile for both attendees and for Nuflow as an exhibitor. Our work continues so if you missed us at Ozwater ’19, you can catch up with our team at and Ideaction 2019 in Sydney from 2-5 June.

For custom solutions to challenging pipe problems, call1800 683 569 (Australia), 0800 168 356 (New Zealand) or visit our contact page to find your nearest technician.

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The problem

Metro Trains were advised by the local water authority that a constant un-metered water leak outside their service depot needed to be repaired immediately. The water main that had failed was feeding the fire hydrant booster for the depot.

It was unknown at the time the leak was identified, but the reason the pipe leaked was the failure of the copper pipe where it joined the ductile steep pipe. The copper acted as a sacrificial anode, causing corrosion, and the copper pipe eventually failed.

To make this repair more complex, the 150mm main pipe ran under a main road. This made it impractical to excavate the pipe to replace and to find the leak. The constant leak had also started to show signs of causing damage to a main road, so the repair was urgent.

The solution

Nuflow South West completed relining the pipe and fixed the leak without causing any disruption to the depot and without the necessity of closing off a busy main road to traffic in only three days.

The cost saving was huge compared with the costs of the traditional ‘dig and replace’ method which takes longer and requires expensive heavy machinery and labour costs.

Additionally, relining the pipe using Greenline has stopped any future failures in the line as the copper pipe will no-longer act as an anode, ending the corrosion permanently.

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