Collex Nodig's New Pipe Lining

AT the recent Pipes Wagga 2001 Collex NoDig Pty Ltd unveiled a new lining product to complement its existing range of rehabilitation technologies. This product, known as Berolina, is manufactured in Germany by BKP Berolina, a firm with over 35 years experience in the design and manufacture of GRP products. 

Collex Nodig’s decision to add Berolina to its product line was made after an extensive review of all available rehabilitation options, world trends and Australian requirements. Judging by the level of interest at Pipes Wagga, the industry agrees with this decision.


BKP Berolina has supplied this product to many parts of Europe a number of years, though the field demonstration in Wagga was the first installation in Australia. Approximately 400m of 150mm diameter liner was installed during the show and the equipment and crew impressed a large delegation of suppliers, contractors and government bodies.

UV cured in place liners are expected to achieve wide market acceptance in Australia if European trends are any indication. Although these systems have been available for less than 10 years, they now hold roughly 50 percent of the German market and this figure is growing on the back of high levels of quality and performance, despite the extremely competitive nature of the market.

The steps in the Berolina system are:

  • The liner is manufactured and delivered to Australia ready to install under strict quality control standards
  • Prior to installation the pipeline is cleaned to remove debris or obstructions and a CCTV inspection is carried out. If necessary defects are repaired by robotics or, in extreme cases, open trench methods.
  • A pre-liner (a thin polyethylene film) is towed in to line the pipe invert. This is protects the uncured liner to avoid damage during installation
  • The liner is winched into the pipeline, after which packers are installed and the liner is inflated to fit tightly within the pipeline. Berolina has the ability to accommodate up to 10 percent variation in shape and size without loss of structural integrity.
  • Once the liner is inflated a light train is inserted and pulled through the section of main being relined. At this time the liner can be pre-inspected before curing commences, using an infrared camera located on the front of the light train. After inspection the light curing commences at factory-specified light intensity and winch speed. The entire process is recorded on computer and video, and the data captured during is sent (via a modem in the lining truck) to BKP in Germany to be checked against the test batch and stored with the manufacturing data.
  • Once light curing is completed the equipment is removed, the liner is trimmed to size within manholes, the junctions are reopened and sealed and the main is returned to service. Unlike most other cured in place systems, there is no need to factor in shrinkage prior to reopening junctions.

It is possible for a crew of only three people to install up to two runs a day, with a maximum length of more than 200m per run. In addition, it is possible to line not only round but ovoid cross sections in diameters of 150-800mm. Each liner is delivered according to the stiffness class specified for each individual project.

The Berolina system offers a proven 50-year design life, structural integrity, computer-controlled installation and data generation and minimal site imprint. Collex No-Dig md and founder Trevor Groeneveld believes that the Berolina significantly outperforms every other lining process on the market today. He is confident that the high and increasing popularity of this system on the global market will be echoed in the Australian market.

Trevor believes that the Berolina system is a significant addition to the range of rehabilitation options offered by Collex NoDig in Australasia, as it is important for a true rehabilitation specialist to offer a range of solutions to suit different conditions and states of pipe deterioration.

The company has branches in Sydney and Melbourne, and is planning to open a branch in Brisbane within the next year.

 Article published with permission
 from Greg Keane of Construction Contractor.

Last Updated on 11 May 2002