Contech Construction ULTRA FLO Installation Manual
ENGINEERED SOLUTIONS
ULTRA FLO® & Corrugated Metal Pipe
Handling and Installation Guide for Reline
PREFACE
This instruction book is for your crews. Distribute it to help them install Contech® ULTRA FLO® and CMP Liner pipe correctly.
ULTRA FLO is a spiral ribbed steel or aluminum segmental pipe that is inserted (sliplined) into an existing deteriorated pipe or
into a casing pipe or tunnel as a carrier pipe. ULTRA FLO features very low wall friction to provide the greatest water ow and
is the most common metal reline pipe. In addition to ULTRA FLO, other corrugated metal pipe (CMP) products can be used
for liner pipe. These additional CMP products include SmoothCor™, HEL-COR®, MULTI-PLATE®, Aluminum Structural Plate and
Tunnel Liner Plate. You Contech representative can assist in using these guidelines along with other CMP products.
Don’t assume experienced workers know all the answers. Review these instructions with your supervisors and crews. It can
mean a safer and better job for you and your customer.
We recommend holding a preconstruction meeting with your Contech representative and all interested parties to ensure
everyone involved in your project has a high level of understanding on what means and methods will be used to prepare for,
install and grout the new structure(s).
If you have any questions about these instructions, call your Contech Representative.
CONTENTS PAGE
Unloading and Safety Instructions ................................................ 3
Preparation for Sliplining ............................................................. 4
Excavating Insertion Pits ................................................................ 4
ULTRA FLO and CMP Lining Insertion ............................................. 5
Jacking Load and Distance ............................................................ 5
Assembling Gasketed Joint ............................................................ 6
Field Cutting Pipe .......................................................................... 7
Annular Space Grouting ......................................…………………..7
Installation Tips ...................................................…………………..9
Curved Sewers, Repairs, Taps ............................... …………………..9
Dimensions and Handling Weights ................................................9
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TERMS YOU SHOULD KNOW
Alerts you to hazards or unsafe practices that
CAN result in severe personal injury or property
damage.
Messages about procedures or actions that must
SAFETY
INSTRUCTIONS
be followed for safe handling and installation of
ULTRA FLO and CMP Liner Pipe. Failure to follow
these instructions can result in serious injury or
death and/or damage to the pipe.
UNLOADING AND HANDLING
The following equipment is recommended for unloading pipe
or pipe bundles:
• Forklift
• Front-end loader with fork adapters
• Backhoe with fork adapters
• Cranes
• Non-metallic slings
Other unloading methods such as lifting lugs, chains, wire
rope, cinching or hooks in the end of the pipe should not be
used.
SAFETY INSTRUCTIONS
1. Only trained and authorized equipment operators are to
be permitted to unload the trailer.
2. Wear approved safety hat and shoes, gloves and eye
protection.
3. Pipe ends may be sharp. Workers handling pipe
must wear gloves made from cut-resistant materials.
4. Park the truck and trailer on level ground before you start
unloading. It is the responsibility of the consignee to
direct the driver to level ground for parking the truck.
5. Keep all unauthorized persons clear of the area when the
driver releases the binders from the trailer and during
unloading.
6. Sometimes pipes are bundled together on the
truck with steel straps. Do not cut the steel strapping
around the bundles until the bundles have been
placed on level ground, blocked or secured, and will
not be moved again as a unit. It is recommended
that the steel strapping be cut with appropriate sized
cutting tools. Stand to the side when cutting a strap.
Always be aware that pipe may move, roll or fall
when a strap is cut.
GENERAL
1. Contech recommends the use of non-metallic slings for
all pipe handling requirements.
2. Hooks, chains or wire rope may damage the pipe.
3. Do not push bundles off the trailer or
permit pipe to drop to the ground.
9. Do not stand or ride on the load of pipe
while it is being unloaded. Do not stand beneath or
near the pipe while it is being unloaded.
10. If unloading at multiple drop-off points, secure the
remaining load and pallets between drop off points.
Always unload the top pallets or bundles rst.
11. The contractor shall be responsible for the safety
of his/her employees and agents. Adequate safety
indoctrination is his responsibility and shall be given to
all personnel employed by his rm.
12. Safe practices on construction work as outlined in the
latest edition of the “Manual of Accident Prevention
in Construction,” published by the Associated General
Contractors, shall be used as a guide and observed.
13. The contractor shall comply with all applicable city, state,
and federal safety codes in effect in the area where he is
performing the work. This conformance shall include the
provisions of the current issue of the “OSHA Safety and
Health Standards (29 CFR 1926/1910)” as published by
the U.S. Department of Labor.
7. Do not lift bundles or sections of pipe
by the steel strapping around the bundles.
8. Know the capabilities and rated load capacities of your
lifting equipment. Never exceed them.
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PREPARATION FOR SLIPLINING
Follow all requirements of the project plans and
specications. Prior to sliplining, the following procedures
should be performed to ensure satisfactory results are
obtained.
1.
2. The existing sewer line should be inspected to determine
3. Verify and record the location, number and size of all
4. Where the pipe is to be pushed through existing
5. Remove any obstructions in the existing line that will
6. Thoroughly clean the existing line as required (high-
7. Verify adequate clearance for the liner pipe. Measure
Ensure continued space assessment procedures
are followed prior to entry.
the condition of the line and identify problem areas
or obstructions such as displaced joints, crushed
pipe, protruding service laterals, roots, debris, out-ofroundness or inside diameter reductions.
inlets and connections.
manholes, check the alignment and clearance.
prevent insertion of, or cause damage to, the new liner
pipe. Large joint offsets or severely deteriorated pipe may
need to be removed or repaired prior to installing the
pipe. These may be good locations for insertion pits or
point repairs.
pressure water, buckets, reamers or other mechanical
methods). Not cleaning the line thoroughly can result in
excessive jacking/pulling loads or liner pipe hang ups that
can damage the new pipe.
the inside diameter (ID) of the existing pipe at the worst
location and compare the dimension to the liner pipe
outside diameter (OD). Depending on the condition of
the existing pipe and the obstructions present, it may
be desirable to pull a trial liner or mandrel of the same
outside diameter as the liner pipe (outside diameters are
listed on Page 19). The trial liner may be a short section
of ULTRA FLO or CMP pipe and should be attached to
pulling cables at each end. If external bands are used, be
sure there is adequate clearance for the band hardware.
SLIPLINING PROCESS
The best specications allow for creativity on how to go
about the reline process. When designed correctly, a project
will have critical performance requirements and information
within the project documents that will provide limitations,
guidance, and perhaps some suggestions on how to
approach the project.
The information contained herein is intended to introduce
some of the techniques that have been used successfully
in the past, and to provide limited guidance on what
needs to be evaluated when considering a particular reline
project. This information does not represent project specic
recommendations from Contech and cannot be construed as
a complete set of guidelines on how to successfully reline a
drainage structure.
Complete and independent project specic evaluations must
be conducted by a qualied contractor prior to them drawing
any conclusions about how to approach a reline project.
The most common method of slipling with CMP is to place
liner pipe one section at a time through the inlet or outlet
end (for culverts) or through an insertion pit (for closed
systems) and to push or pull the single sections into nal
position. Handling just one section at a time is normally the
most efcient as it minimizes the amount of weight being
pushed or pulled.
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