Kembla Watertech P/L is a specialist pipeline rehabilitation contractor who has been a leader in this field since 1993 and the company offers a number of different No Dig spot repair systems. In the past, if a home-owner happened to have an access chamber inside their property then a number of separate visits by different crews and equipment were necessary to complete the rehabilitation of the pipeline. This was disruptive and inconvenient for all parties.

As an industry leader, Kembla realised the advantages for both the client (typically a water authority) and the customer (the householder) if the number of separate visits to a site could be reduced. The company also identified that cost savings would also result from the associated increased efficiencies.

Calling on their 12 years of practical experience in this field the engineering department designed and built multipurpose pipeline rehabilitation units capable of completing a number of different tasks, minimising the number of return visits to a particular site.

Each of these trucks is fully self-contained with a super-silenced diesel generator (69 dB at 3 m) which provides the power to on-board compressors, computers and other electrical equipment.

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Each truck is equipped to undertake the following spot repair work:

• CCTV inspection cameras to locate and identify the problem • De-rooting of junctions from inside the mainline • Installation of Tiger Patch short form structural pipe repair • Installation of FlexiLiner house service linings • Installation of Tiger T structural repair and sealing of pipe connections • Beaver pipe re-rounding • Post survey of completed rehabilitation projects.

The small ‘footprint’ of these trucks on site and their low noise rating (even less than 69 dB when generator cabinet is closed) makes them ideally suited to small back streets and after hours emergency work. All resin mixing for the various systems is done under a safe and controlled environment inside the truck body. There is sufficient material storage for the units to be self sustaining when sent away from their home base.

These units have proven so successful and have received such positive feedback that the company now operates them out of all their offices in Sydney, Melbourne, Newcastle, Brisbane and Townsville.

Beaver Pipe re-rounding system

Deformation of pipe sections is a common problem in old sewers. There are instances when a pipeline may have only one or two points with a localised defect that is preventing the installation of a no-dig rehabilitation solution. In the past, this type of defect has required excavation and replacement of these sections prior to carrying out further rehabilitation. If these deformed sections happen to be located under paved roads or buildings then the cost of excavation may be prohibitive. One of the spot repair technologies offered by Kembla overcomes this problem and is unique in Australia. The Beaver H-Expander system is a localised pipe re–rounding technique requiring no excavation.

The Beaver H-Expander has an independent nose cone that opens up under hydraulic pressure and forces back the deformed pipe sections. This clears the way for the main hexagon shaped expanding section to apply up to 32,000 kg of lift which forces the fractured pipe pieces back into a circular shape and at the same time supplies the damaged area with a supporting stainless steel sleeve. The 500 mm long sleeve is made from high corrosion resistant austenitic stainless steel AISI grade 316 and incorporates a ratchet lock system which locks itself to the exact diameter of the old pipe. Additional sleeves placed in series enabling longer repair lengths. Where required, the repaired section can be finished with a Tiger Patch or a full length lining such as Ex Method.