PI.TRON filling & grouting system – a proven procedure for sewer rehabilitation

Overview

The PI.TRON filling & grouting system enables high-precision and flexible work on partial repairs of damaged areas as well as the rehabilitation of connectors in sewer tunnels with diameters of DN200 to DN800 as well as all known oval profiles.

Filling robots SR 178 and SR 300, shield injection robots SM 200 and SM 300, plus an extensive selection of accessories are part of Pipetronics' filling & grouting system. Rehabilitation using the PI.TRON filling & grouting procedure has proven itself several hundreds of thousands of times in rehabilitation practice with similar systems.
 


 

 

 

Description – Detail

The two available Pipetronics filling robots are equipped with an axial and longitudinal spatula for filling. Combined with an infinitely variable electrical drive and rotational drive, these tools ensure control with millimetre accuracy that can also be used to rehabilitate complex types of damage in a lasting and form-fitting manner. A large selection of accessories is available for implementation, for instance shuttering without hole or with hole diameters of 100, 120, 150, 180 and 210 mm, sleeve shuttering or tension belt / gear racks for all diameters from 200 to 800 mm.

The hydraulic and electrically powered milling robots from Pipetronics can be retrofit with the filling & grouting system to become all-in-one systems. In addition, the filling & grouting system can be deployed as a modular solution in combination with milling robots produced by other manufacturers. In this way, cutters made by other brands can be upgraded with reliable technology at a fair price. 

The application spectrum of the PI.TRON filling & grouting system includes:

Tight integration of domestic connections in the main sewer with and without a liner

The PI.TRON procedure has proven itself in the rehabilitation of domestic connections with a shuttering that can be connected to the filling robot. Sewer maintenance providers can thereby satisfy the legal requirements existing in many places for long-lasting tightness of connections between main sewer channels and domestic connections – in other words, there is no discharge of waste water into the groundwater (exfiltration) or entry of groundwater into the sewer.

If no liner is fed into the sewer, after completing the milling work and removing the milling mud, the robot travels with the shuttering cuff and a plastic shuttering to the affected domestic connection and positions a rubber sealing bag there to shut off the inflow. Using two sliders, an epoxy resin is pressed into the hollow space created behind the shuttering. A plunger presses the epoxy resin into the damaged area through a tube using compressed air. After a few hours of curing the connection is durably leak-proof. About 500,000 domestic connections around the world have been sealed using this procedure.

The following work steps are necessary for sealing domestic connections in the main sewer:
1. General preliminary work (milling work, measuring the connections being rehabilitated to prevent faulty drilling later on when opening the liner)
2. Opening the inliner with the milling robot
3. Adequately deep milling of the soiled connections using the robot Grinding the liner edge
5. Relief milling the liner
6. Cleaning the adhesive surface
7. Setting the shuttering cuff and the rubber sealing bag
8. Filling/grouting the shuttered cavity behind the sleeve with epoxy resin
9. Removal of the shuttering cuff and the sealing bag from the sewer

Repair of leaking pipe connections with the sleeve shuttering

After high-pressure cleaning of the damaged section, the area being rehabilitated is milled out sufficiently deep in accordance with the material manufacturer's guidelines. After the milling mud has been removed, the shuttered damaged area is grouted/filled in accordance with manufacturer specifications. Finally, the formwork is removed and any post treatment can be carried out, if necessary. Rehabilitation with sleeve shuttering is possible with a groundwater level of up to 1.5 m, depending on the existing conditions.

Filling longitudinal and lateral cracks

After the necessary preparatory work has been performed, like the removal of deposits, the sewer robot mills out the existing crack in a trapezoidal shape to a sufficient depth with the aid of a groove cutter. The residual milling mud is then removed with the water jet technology on the robot or with a different rinsing vehicle. The filling robot then fills the grooves in the area of the crack with epoxy resin. Depending on the damaged area various filling tools or crack shuttering can be utilised. After the epoxy has cured, any existing burrs or uneven surfaces are removed using tools (e.g. a wire brush) that do not damage the enamel of the pipe.

Repairing holes and sealing connections

Repairing holes or sealing lateral inflows is performed using the same procedure as the crack repair described above. However, particular attention must be paid to the following difference: The frontal sides of the pipe wall are milled out at full power until the loose and/or soiled parts of the pipe material have been removed. Foreign objects that jut out in the cross-section of the outside diameter of the pipe must be milled back sufficiently deep. Holes with a large diameter should generally be worked on with shuttering that is considerably larger than the damaged area and that have a curvature that corresponds to the nominal width of the pipe.

Suitable for epoxy resins

Pipetronics' filling & grouting system is suitable for work with epoxy resins. Depending on the manufacturer, either all-round resins are available for all damaged areas or special resins for specific repair areas (sleeve resin, filling resin, shuttering resin etc.). As a full-service provider we also carry resins in our product range. Find out more about our assortment of resins here.

 

 

Technical data

Filling robots

Filling robot SR 178

Drive type Electric
Pipe diameter 178-300 mm
Total length 1030 mm
Weight 35 kg
Filler cartridge content 1.8 l
Extension distance 80 mm
Rotation 670°

Filling robot SR 300

Drive type Electric
Pipe diameter 250-800 mm
Total length 980 mm
Weight 55 kg
Filler cartridge content 2.75 l
Extension distance 88 mm
Rotation 560°

Shield injection robots

Shield injection robot SM 200

Pipe diameter 200-300 mm
Length with robot 1160 mm
Weight without robot 11 kg

Shield injection robot SM 300

Pipe diameter 300-800 mm
Length with robot 1170 mm
Weight without robot 8 kg

Photos

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Exceptionally flexible: Pipetronics' filling and grouting system PI.TRON
Exceptionally flexible: Pipetronics' filling and grouting system PI.TRON
Exceptionally flexible: Pipetronics' filling and grouting system PI.TRON
Exceptionally flexible: Pipetronics' filling and grouting system PI.TRON
Exceptionally flexible: Pipetronics' filling and grouting system PI.TRON
Exceptionally flexible: Pipetronics' filling and grouting system PI.TRON
Exceptionally flexible: Pipetronics' filling and grouting system PI.TRON
Exceptionally flexible: Pipetronics' filling and grouting system PI.TRON
Exceptionally flexible: Pipetronics' filling and grouting system PI.TRON
Exceptionally flexible: Pipetronics' filling and grouting system PI.TRON
Exceptionally flexible: Pipetronics' filling and grouting system PI.TRON
Exceptionally flexible: Pipetronics' filling and grouting system PI.TRON

Contact

What can we do for you? Contact us to find out more about the PI.TRON filling & grouting system. We are here to assist you by telephone at +49 (0) 6349 99 049 - 0 or e-mail at info(at)pipetronics.com. We look forward to getting in contact with you!