Plastiline™ - Humes

Plastiline
BUILD ON OUR EXPERTISE

CONTENTS
Introduction......................................................................3
Summary of principal properties .....................................5
Resistance to aggressive agents.......................................5
Utilisation.........................................................................6
1 Principal applications .............................................6
2 Degree of lining required.......................................6
3 Pipe sizes and classes.............................................7
4 Fittings ..................................................................7
5 Protection for concrete cast insitu..........................7
6 Plastiline project applications .............................8
Specifications ...................................................................9
1 Composition .........................................................9
2 Manufacture.........................................................9
3 Dimensions ...........................................................9
4 Chemical properties ..............................................9
5 Physical properties ................................................9
6 Incorporation in spun concrete pipes ..................10
7 Incorporation in vertically cast pipes ...................10
8 Laying and jointing .............................................11
9 Incorporation of keyed Plastiline
in cast insitu concrete structures..........................13
10 Methods of jointing.............................................15
11 Testing.................................................................17
12 Repairs ................................................................18
13 Handling - storage - laying..................................18
14 Periodical inspections...........................................19
2

INTRODUCTION
1 The material and its function
Plastiline is a plasticised PVC sheet specially designed to
be embedded in concrete as a surface protection. Shaped
keys provide a mechanical lock with the body of the
concrete. Welding strips and other accessories of the same
formulation and quality as the sheet are readily available.
The prime function of Plastiline is the protection of
concrete against hydrogen sulfide (H 2 S) attack. It is
equally effective against a wide range of acids, alkalis
and aggressive salt solutions.
Plastiline offers complete protection and is suitable for
applications which include sewers, treatment works,
industrial waste lines, storage tanks - in fact, any concrete
structure where aggressive agents are encountered.
Synthetic PVCs of high molar mass have proven
outstanding resistance to aggressive agencies, both in
laboratory tests and under exacting service conditions.
The use of a continuous PVC liner to protect sewers and
sewerage structures is now backed by nearly 40 years of
service experience, with installations in Australia, Saudi
Arabia, Singapore, Malaysia, Bahrain, The United Arab
Emirates, Iraq, Fiji, Taiwan, Thailand, Turkey, Japan,
Indonesia, Hong Kong, New Zealand and Pakistan.
2 Plastiline profile types available
Keyed Plastiline: Designed for use in all situations where
mechanical interlock can be achieved - all concrete pipes
and most insitu concrete structures and maintenance holes.
Plain Plastiline: Designed for use in bonding
applications or situations where no keys are required.
Plain Plastiline
For standard Plastiline sheet A = 1240 ± 6 B = 52 ± 3 C = 52 ± 3 D = 0
For special Plastiline sheet A = 1318 ± 6 B = 129 ± 6 C = 52 ± 3 D = 4 ± 1
Narrow sheets available to order.
Note: Other profile keys may be available for special projects.
Contact CSR Humes for advice.
Section of Humespun pipe showing Plastiline keys embedded
directly into the pipe wall.
3

Standard accessory strips
3 Development
The problem of H 2 S attack (which results in sulfuric acid
attack) has been recognised for more than 60 years.
It causes serious deterioration in concrete sewers and
structures if the requisite concentrations and conditions
occur. Attack is usually encountered only in larger sewers
or under unusual circumstances.
Since 1956 Humes has investigated both in the laboratory
and in the field, many methods of protection against
concrete corrosion, especially that due to H 2 S attack. H 2 S
attack encountered in sewers is biochemical and
conditions causing such an attack cannot be simulated in
the laboratory. For this reason we have conducted actual
sewer tests over many years, using facilities made
available by the Melbourne and Metropolitan Board of
Works (Melbourne Water) and other authorities. Results of
this research clearly indicated that a continuous PVC sheet
lining does provide a most effective protection
for concrete under these aggressive conditions. This
conclusion led to a development program in conjunction
with Nylex Corporation Limited, resulting in Plastiline
in its various formulation and profile types to suit
different applications.
4 Manufacture
Plastiline is manufactured by modern extrusion
processes which transform the high polymer PVC resin
granules into a dense impervious sheet completely free
from flaws. The continuous Plastiline sheet can be cut
and used as extruded or it can be factory assembled into
custom blankets of any shape and size.
For custom blankets the joints are factory welded with hot
air equipment to give a high quality lap weld.
During manufacture every sheet is permanently marked
with its batch identification. All sheets and accessories are
100% spark tested at the factory. As may be expected,
strict quality control is exercised during manufacture, and
test certificates of physical and chemical properties are
available on request.
Normally Plastiline sheet is black, but white sheet
may be produced to order for applications where light
reflection is required for greater visibility. Other colours
may be produced as an easy means of identifying special
formulations, manufactured to meet specific uses.
Samples of pipe subjected to a corrosive environment.
L-R: Siliceous Aggregates, Coarse Calcareous Aggregate and
Course and Fine Calcareous Aggregates.
Plastiline installed in pipe at moulding stage.
4

SUMMARY OF PRINCIPAL
PROPERTIES
1 Tensile strength
Longitudinal and transverse tensile test results exceed
17 MPa. This strength combined with excellent
mechanical interlock of keys in concrete means permanent
fixture. Weep channels prevent build-up of back pressure
caused by any moisture behind the sheet, except in the
case of fully-lined structures, where special precautions are
required.
2 Elongation
Not less than 225% at failure and together with the
tensile strength allows coverage of flexible joints without
damage to the lining.
3 Porosity
Gases and solutions will not penetrate Plastiline.
The sheet is an homogeneous extrusion, free from
pinholes. Spark testing at at least 10,000 volts after
manufacture checks the entire surface of all sheets.
4 Plasticiser permanence
Use of a stable plasticiser ensures high plasticiser
permanence. Samples recovered from live sewers after up
to 30 years in service validate this performance property.
Also the laboratory testing determined loss of plasticiser
under vastly accelerated test conditions at 90 O C does not
exceed 1%.
5 Weldability
Jointing and sealing together sections of Plastiline is
readily achieved by a trained operator using a heat fusing
process. The resultant weld is equivalent in protection to
that of the parent sheet.
6 Temperature effects
Flexibility of the sheet increases with rising temperatures
but otherwise this material is not affected by the normal
range of ambient temperatures. In most cases Plastiline
is suitable for pipeline temperatures normally encountered
and up to 80 O C for limited periods not exceeding 24 hours.
Normal steam curing of concrete does not affect
Plastiline except for temporary softening of the sheet.
7 Embedment
Keys are designed for easy embedment during the pipe
lining process and to give positive mechanical lock into the
pipe or structure. Keys will withstand a test pull
normal to the concrete, equivalent to a minimum of
14 N/mm length of key, refer Clause 11.4 page 17.
8 Water absorption
At a temperature of 23 O C the maximum water absorption
is 0.10% after 24 hours. This low percentage illustrates the
fact that water penetration is negligible and the sheet forms
an impermeable barrier.
10 Tear strength
The value of 80 N/mm minimum tear strength, both
longitudinally and transversely, reflects the toughness
of the material. Although a sharp instrument may
puncture it, there is no tendency for the perforation to
progress further.
11 Abrasion resistance
Plastiline possesses higher abrasive resistance qualities
than concrete itself. Recommended velocity limits in
sewers are 6 m/s in straight sections and 3 m/s at curves.
12 Food contact
Standard Plastiline should not be used to line food
containers.
13 Combustion
Plastiline will not support combustion.
RESISTANCE TO
AGGRESSIVE AGENTS
The ability of PVC to resist deterioration when exposed
to a wide range of chemical substances is well known.
Some of the more common substances which can collect in
sewers as effluent from industrial processes are listed
below. For information on the resistance of PVC to other
substances, enquiries may be made to Humes.
1 Acids
Completely unaffected by almost all dilute mineral and
organic acids, including sulfuric, nitric, lactic and malic.
It is also unaffected by some concentrated acids, provided
certain temperature limits are not exceeded.
2 Alkalis
Resistant to concentrated alkalis such as caustic soda,
quicklime and ammonium hydroxide.
3 Aggressive salts
Exposure to salt solutions which attack concrete or
reinforcement reveals no loss of endurance.
These include ammonium nitrate, sodium chloride, ferric
chloride, sodium hypochlorite and sulfates.
4 Organic compounds
Withstands action by soaps, detergents, oils (animal,
vegetable, mineral), fats, greases, and waxes.
5 Solvents
Insoluble in all common alcohols, glycol and glycerine.
Not recommended for applications where chlorinated
hydrocarbons, esters, ketones and similar solvents are
present.
6 Petroleum products
Suitable for use where petrol, diesel oil, and crude oil
are encountered intermittently as in sewers.
7 Chlorine
Resistant to chlorinated water and sewage. Direct
exposure to chlorine gas may cause deterioration.
5

UTILISATION
1 Principal applications
• Lining of spun pipes
• Lining vertically cast pipes
• Lining of cast insitu pipes
• Lining of maintenance holes
• Lining insitu structures such as
pumping stations and treatment plants
• Pile protection
• Precast concrete component protection
• Basement linings
• Tank linings for chemical
manufacturing plant
2 Degree of lining required
For minimum cost only those areas of the pipe surface which
are likely to be attacked need to be lined. The area needing
protection will vary with different service conditions. There are
basically two conditions:
H 2 S attack conditions only
The sequence of H 2 S attack - which finally produces acid
which corrodes the concrete - occurs only under particular
conditions of age, temperature, flow, sulfide content, etc.,
of the sewage. Only the concrete which is above the
minimum flow line will undergo attack, and hence lining
and protection is only needed above this flow line.
For medium and large sewer pipes the degree of partial lining
(see illustation) may only need to be 300 O or even less
leaving 60 O or more of the pipe invert exposed, which is not
at risk because it is covered by the flowing sewage. This is
particularly applicable to large trunk sewers.
There are situations where the lining must cover most
of the pipe surface. These are more common for
smaller diameter pipes DN 375 - 600 although
occasionally up to large sizes such as DN 2100. Such
linings are conventionally known as 359 O linings
(see illust.), although this does not mean that the full 359 O
will be covered.
0 = DEGREE
OF LINING
INVERT
GAP
Tolerance variations on pipe diameter and cutting the
Plastiline to size will mean that there can be a gap at the
invert varying from a few millimetres for small pipes, 50mm
for medium size pipes and 150mm for large pipes. Even a
few millimetres depth of sewage flow will cover any
exposed or unlined section.
Figure 1: Diagrammatic representation of the “H 2
S attack” mechanism.
SEWAGE
INORGANIC SULFIDES
ORGANIC COMPOUNDS
SULFATES
SULFUR
BACTERIA
AMMONIA CO 2
ETC. IN AIR.
SLIMES
BACTERIAL ACTIVITY FORMS
SULFIDES
INSOLUBLE - METALLIC SULFIDES
OXIDISED - MAINLY SULFUR
SOLUBLE IONISED
FRACTION
GAS EMISSION
TOTAL SULFIDES
SOLUBLE SULFIDE
DISSOLVED H 2 S
ATMOSPHERIC H 2 S
H 2 S
SILT
SLIMES
H 2 S AND O 2 ON PIPE WALL
BACTERIAL ACTION,
PROGRESSIVE PH REDUCTION
TO SULFURIC ACID
6

Industrial waste lines
Where such pipelines can carry wastes which are directly
aggressive to concrete (either separately or in conjunction
with H 2 S attack) it is recommended that pipes are 360 O
lined.
In these instances the pipe is first lined with a 359 O lining
and the resulting unlined invert gap is sealed by one of two
alternative methods, (see illust.) so as to completely protect
the invert.
Pipes lined with 360 O should not normally be buried more
than 3m below the highest level of the water table. This
will depend on circumstances and Humes will advise on
individual applications.
4 Fittings
All types of fittings can be supplied for use in combination
with Plastiline pipe. Offtakes may be PVC, clay or concrete
fitted to any diameter parent pipe. Bends and junctions
made from concrete and protected by Plastiline can also
be manufactured to order. Attachment of such fittings to
provide a completely protected sewer system is described in
later pages.
DN 1650 sewerage pipe, Plastiline, with custom designed
DN 1100 maintenance hole Tee junction.
3 Pipe sizes and classes
Concrete pipes of all classes ranging from DN 375 upwards can
be lined with Plastiline.
5 Protection for concrete cast insitu
When used to protect centrifugally-spun concrete pipes the
Plastiline sheet is forced into the green or uncured concrete
using vibration to embed the keys. Plastiline may also be
used for protecting the exposed surface of concrete in insitu
structures such as sewage treatment works, flumes carrying
aggressive wastes and tanks containing aggressive chemicals
for industrial processes.
In these applications the formwork for the structure is erected
in the usual manner. Plastiline sheets are then attached to
this formwork and held in place with the keys projecting
towards the space to be filled with concrete. Joints between
the Plastiline are temporarily protected with adhesive tape
and reinforcement is then placed in position.
Concrete is then placed in the normal manner.
After curing, the formwork is removed leaving the Plastiline
firmly embedded. The joints are then permanently sealed by
welding with cover stips.
If required, special prefabrication of the Plastiline into
complicated shapes and patterns enables protection to be
provided to geometrically involved parts of structures such
as ducts and venturis.
Jointing DN 450 pipes with Plastiline.
Field welding Plastiline during construction of the Elanora
Treatment Plant on the Gold Coast, Qld.
7

6 Plastiline project applications
The Plastiline System was initially developed for use in
sewerage systems and millions of square metres have been
used in every aspect of these systems both in Australia and
overseas.
Plastiline is installed in sewer pipelines in:
• Bagdad and Basra and other Iraqi cities
• Riyadh, AI Khobar and other Saudi Arabian cities
• Suva, Fiji
• Singapore and Malaysia
• Bangkok, Thailand
• Abu Dhabi, Dubai and other UAE cities
• Istanbul, Turkey
• Tokyo and other Japanese cities
• Bahrain
• Jakarta, Indonesia
• Hong Kong
• New Zealand
• Pakistan
and many other overseas locations.
A sewerage pipe (Plastiline) installation in Western Australia.
DN 1950 sewerage pipe, Plastiline, class 4 jacking pipe going
under the Geelong Racecourse and nearby Fellmongers Road.
Plastiline has been used in every Australian State and
Territory, not only in pipelines but also to protect every
concrete structure associated with the collection,
treatment and distribution of the sewage, for example:
• In Queensland, for the Bundaberg Sewerage Authority
digestion tank.
• In New South Wales, for the Sydney Water North Head
Sewerage Treatment Works primary treatment tanks.
• In Victoria, for Melbourne Water Carrum Treatment
Plant and the Melton Sewerage Authority effluent
treatment.
• In Western Australia and other states for protection of
precast and insitu maintenance holes.
However, Plastiline usage is not confined to the
sewerage field - it can be used to protect concrete
wherever aggressive agents are encountered. For example:
• Protection against aggressive chemicals stored in tanks.
– Victorian Winnekie Reservoir water treatment plant,
alum storage tanks.
– Acid descaling tanks, Johnsway Plant.
• Protection of buried concrete against aggressive
ground waters.
– Animal National Health Laboratories basement, Victoria.
– Newport Power Station basement, Victoria.
Inlet duct form covered in Plastiline being lowered into
position in the main pumping station of the Rama IV Drainage
Project, Bangkok.
Junction of DN 1950 and 600 Pipes at the Beenyup Treatment
Works.
8

1 Composition
1.1 All Plastiline sheet (keyed and plain) and all
accessories shall be composed of high molar mass polyvinyl
chloride combined with plasticisers, stabilisers and
pigments compounded to make permanently flexible
sheets. Copolymer resins shall not be permitted and
polyvinyl chloride shall constitute not less than 99% by
mass of the resin used.
2 Manufacture
2.1 Manufacture of sheet and accessories
2.1.1 All Plastiline sheet and accessories shall be
produced by extrusion or injection moulding under
controlled temperature and pressure conditions. Keyed
sheets shall be produced by extruding the key integrally
with the sheet and using the same material as the sheet.
2.1.2 During manufacture every sheet produced from a
‘batch’ of compound shall be permanently marked with the
batch identification. The sheet shall be 100% spark tested
for continuity, using spark testing equipment which
generates a minimum of 10,000 volts.
2.2 Fabrication of blankets
2.2.1 Blankets shall be fabricated from individual sheets or
part sheets using automatic hot air welders.
2.2.2 The joints shall be formed by lap welding sheets
parallel to the keys, with a lap not less than 20mm and
a weld width not less than 14mm.
2.2.3 All joints shall be probe tested in accordance with
clause 11.2. The tensile strength of samples taken from the
joint and tested transverse to the joint shall be not less than
20 N/mm.
2.2.4 If a field joint type P2 (see page 11) is required,
it shall be provided by the use of a special sheet (see
page 3) with its wider flap when fabricating the blanket.
2.2.5 Where the required blanket dimensions cannot be
obtained by welding selected material parallel to the key,
the alternatives are to either:
(a) remove keys to form a 50mm wide flat section on
each sheet, lap the sheets and weld as described in 2.2.2
or
(b)
SPECIFICATIONS
butt the sheets and weld strip on the smooth side of
the sheets. This procedure is not recommended except in
factory conditions when adequate support and alignment
of the abutting edges can be ensured.
3 Dimensions
3.1 Sheet dimensions for both standard and special keyed
sheets are given on page 3.
3.2 The mass of the standard sheet (1240mm wide) per
metre run shall be not less than 3.3 kg for keyed sheet.
3.3 Blanket dimensions can be tailored to suit any
installation purpose - the size limitation is in handling.
Requirements should be discussed with your local Humes
representative.
4 Chemical properties
4.1 Using the test method of ASTM D 543 the change in
mass of Plastiline when exposed to the chemicals
listed below shall be determined.
Specimens of identical area and with keys in identical
positions shall be used in all tests. The change in mass shall
not exceed the percentage shown. Sample size shall be
75mm x 25mm by thickness of sheet.
Chemical Agent
Sodium Hypochlorite 0.20
(1% as available chlorine)
Ferric Chloride 1% 0.60
Sodium Chloride 5% 0.15
Sulfuric Acid 20% 0.12
Nitric Acid 1% 0.20
Sodium Hydroxide 5% 0.20
Ammonium Hydroxide 5% 0.40
Soap, Detergent Solution 2% 0.40
5 Physical properties
Maximum % change in mass of
Plastiline over 7 days at 20°C
5.1 The Plastiline shall meet the requirements
stipulated herein and test certificates can be supplied
if requested.
Physical Property Test Method Acceptable Limits
Tensile Strength
(both longitudinal
and transverse to key)
Elongation at Break
(both longitudinal and
transverse to key)
Hardness
Plasticiser Permanence
(24 hours at 90 O C on
50mm diam. disc)
Water Absorption at
24 hours (sample size
76mm x 25mm by
thickness of sheet)
Water Soluble
matter at 24 hours
Tear Strength (both
longitudinal and
transverse to key)
ASTM D 412
ASTM D 412
Shore durometer
D at 23 O C
ASTM D 1203
Method B
ASTM D 570
ASTM D 570
ASTM D 1004
(Grip Speed 8.5
mm/s)
17.25 MPa min.
225% min.
54 min. - 62 max.
1.0% max.
0.10% max.
0.05% max.
80 N/mm
minimum
9

6 Incorporation in spun concrete pipes
6.1 The Plastiline shall be incorporated in the body of
the concrete pipe by embedment of the locking keys in the
concrete immediately following the manufacture of the
pipe.
6.2 The Plastiline blanket shall be so placed in the pipe
that keys are circumferential in direction. This will allow a
free escape to the unlined part of the pipe for any moisture
or fluid which may accumulate between the lining and the
pipe wall.
6.3 The extent of the pipe circumference to be covered
by the Plastiline shall be specified by the client. It is only
necessary to line that area of concrete which is subject to
corrosion (see page 6).
6.4 Immediately upon completion of manufacture of the
pipe the Plastiline is to be accurately positioned in the
pipe and the locking keys fully embedded in the concrete in
such fashion as to develop the pull-out strength stipulated
in Clause 11.4.
6.5 Keys adjacent to the ends of the pipe barrel shall not
be closer than 13mm to the ends of the barrel and the
maximum distance between keys on either side of a pipe
joint, with an undeflected pipe fully ‘home’ shall not
exceed 130mm for field welded pipes. For factory welded
pipes incorporating spigot end caps and/or socket inserts,
the distance of the first key from the pipe end shall not
exceed 130mm.
6.6 Embedment of Plastiline into concrete pipes can
produce minor circumferential corrugations which will be
more evident in smaller diameters. These corrugations
shall be in addition to the tolerances allowed under
Australian Standard AS 4058 and will have no significant
effect on the carrying capacity of the pipes because of
the smoothness of Plastiline and the smooth flow
conditions.
7 Incorporation in vertically cast pipes
7.1 Plastiline sheet shall be so placed on the inner
mould that keys are running in the longitudinal direction.
A short length of each locking key shall be removed to
provide weep channels at intervals of no more than 2.5m
along assembled pipelines, to ensure that there is no
build-up of hydrostatic pressure.
7.2 The sheet shall be placed under slight tension and
held firmly against the inner mould, to prevent leakage of
mortar between blanket and mould. The sheet can be a
pre-formed tube, or blanket held in place initially by metal
or plastic straps and finally secured at the vertical edges
under strips of rigid plastic, held by screws inserted from
inside the mould.
If the lining is a pre-formed tube, relief of hydrostatic
presure is provided by leaving a short length of the
circumference unwelded (at the invert) when the pipeline
is assembled.
7.3 Reinforcement shall be secured by plastic bar
chairs or other method of support which will not damage
the sheet.
7.4 In large diameter vertically cast pipes, adjacent linings
will normally be joined in the assembled pipeline by
102mm joint strip as shown in the joint detail type P1
(see page 11).
2250mm diameter Plastiline pipes.
10

8 Laying and jointing of pipes lined
with Plastiline
8.1 This section of the specification is not intended to
cover the laying and jointing of the basic concrete pipe but
deals with the additional jointing requirements arising from
the lining only.
It is essential that care should be taken to prevent damage
to the lining during handling and laying of the pipe.
When pipes lined with Plastiline have been laid and
jointed to form a pipeline, the concrete surfaces at the
circumferential joints must be protected either by
connecting and sealing the linings or by constructing a
special joint.
8.2 Field welded joints shall be either Type P1 or
Type P2.
Type P1 — Special Pipe Joint
using cover strip for butt or flush
or spigot & socket joints or for
pipe to structure
8.3 Field welding of strips associated with joint types P1
and P2 shall be carried out by qualified PVC welders using
approved methods and techniques.
8.4 Welding operators must be trained and accredited by
Humes before welding field joints. Proof of welding ability
is required prior to commencing work and approval is based
on the result of tension tests on three sample welds. The
test is carried out according to ASTM D 412 with the
tension transverse to the line of the weld. All samples shall
reach a stress of 13 MPa in the Plastiline sheet away from
the weld, without failure.
8.5 The technique of welding requires the weld strip
to be heat-fused to both sections of the sheet overlapped
by the strip. Particular attention must be given to ensuring
the surfaces to be welded are quite clean and for this
purpose the cleaning agent Applied Chemicals 4480 is
recommended.
8.6 In order to obtain a good quality weld the operator
must achieve the correct temperature to just bring the
mating surfaces to a semi-molten condition. Sufficient
pressure must be applied to force the molten surfaces into
intimate contact until the weld has solidified. Attention
must be given to obtaining weld beads on both sides of the
weld strip (see illust. below). After welding, beads should
be visible on both sides of the weld strip.
Care must be taken not to overheat the Plastiline during
welding. It should be noted that a temperature of 200 O C
or more can cause decomposition of the material. Charring
is evidence of too high a welding temperature.
Type P2 — Normal Pipe Joint
using flap for spigot & socket
joint or butt or flush joints;
straight pipes only
The use of a 100mm flap will not be permitted for splay joints in
reinforced concrete pipelines. Plastiline at splay joints shall be
joined with a type P1 joint.
The Type P1 is used for short length pipes and for splay
joints, and is made by placing a joint strip over the joint,
which is secured and sealed at the edges using two
weld strips.
With the Type P2 joint, which is the most frequently used
for full length pipes in diameters 600mm and larger, a plain
flap of unkeyed lining at the spigot end of one of the
jointed pipes is lapped over the lining of the adjacent pipe
and sealed with a single weld strip.
Plastiline welding plant.
11

8.7 When required by the client, at the commencement
and completion of the welding of each joint a 50mm
length of unfused welding strip can be provided to form
a test tab.
8.9 Where sewer lines incorporate maintenance holes the
components can be supplied precast and lined with
Plastiline. These include the shaft, slab, riser and top.
8.8 Special pipe joints are available for small diameters in
some applications.
NOTE:
Shafts, chambers and risers are 360º
lined. Keys run circumferentially and
sections of keys are removed to create
weep channels as per Clause 9.3.
*Denotes field operation
12

9 Incorporation of keyed Plastiline
in cast insitu concrete structures
9.1 The Plastiline must cover the areas specified and is
secured to the inner formwork face prior to placing the
concrete and reinforcement. Formwork used must be
suitable for proper attachment of the plastic sheet.
The preferred method of attachment of the sheet is by
nailing or stapling directly to timber forms, or to timber
nailing strips set in steel forms at the appropriate
positions. Nails shall be of approved small flat-headed
type. All fasteners must be placed within 7mm of the edge
of the sheet so that holes will be covered by the welding
strip. If it is necessary to secure a joint flap a temporary
form support must be used and the flap must be fastened
within 7mm of its edge.
Alternatively, it can be held to steel forms by light metal or
plastic bands tightened on to suitable attachments to the
forms. Provision must be made to maintain the sheet in
close contact with the form during concrete placement.
Bands must be of the type recommended by Humes.
If the bands cross the keys, provision must be made to
ensure that the keys are not bent or distorted.
All pipe or other metal inserts must be held firmly in place
on the formwork and, where required, the Plastiline
protection of these inserts must first be installed. Metal
form ties shall be kept to a minimum.
9.2 In the case of large floors or the bottoms of large
tanks etc the alternatives are:
i) Where there is no external hydrostatic head or other
potential uplift, plain Plastiline sheet or blankets can be
loose-laid or bonded to the base slab with an adhesive
approved by Humes.
ii) Where the base can be subject to pressure from
external ground water, Plastiline should be embedded
into the top of the slab, using a vibrating screed. This
vibrator is applied after bleeding has ceased, but before
initial set occurs.
As it is essential to insert the keys before the concrete
hardens, it may be necessary to limit the area of each pour.
iii) After vibrating the Plastiline into position, if
sheets/blankets overlap, care must be taken to ensure
concrete mortar is cleared from welding areas prior to the
complete hardening of the concrete.
9.3 Unless otherwise specifically indicated, Plastiline
blankets shall be positioned so that the locking keys are
vertical or as near vertical as possible to provide a free
escape to the bottom of fluid which may accumulate
between the lining and wall of the structure. Where the
locking keys cannot be positioned vertically a gap of
between 75mm and 100mm width shall be provided by
cutting off the locking keys at intervals not greater than
2.5m longitudinally, to provide weep channels. A weep
channel shall be provided approximately 300 mm away
from all lining returns.
Where changes in direction or corners are encountered, the
Plastiline may be bent and secured to the form, provided
the radius of the blend is not less than 25mm.
Where sharper corners are specified, a jointing method
approved by Humes must be used.
9.4 For lining joints which do not correspond to joints
in the concrete structure, the Type C3 joint is preferred. For
this joint the Plastiline sheets are butted together,
so that the gap between sheets and/or blankets at
any position does not exceed 4mm. This gap must be
temporarily sealed by a wide PVC tape before placing
concrete. After form removal a flat welding strip, centred
over the gap, is welded to give a permanent and
continuous lining on the inside of the structure.
As an alternative, the lap joint Type C2 may be used.
This joint requires that the Plastiline be lapped at least
35mm, the overlap or flap being on the downstream side
of the joint. A Type C2 joint must be at longitudinal
construction joints in concrete structure.
For Plastiline lining joints at transverse construction or
contraction joints in the concrete structure, a Type C1 joint
must be used.
Normal jointing method C1
This is identical with type P1
Normal jointing method C2
Note: Type C1 Joint is identical with type P1
Min. overlap 35mm
Flat Welding Strip
Direction of flow
PVC Tape
Use seam weld or apply pvc
tape before placing concrete.
Method of jointing Plastiline in structure without joint.
Not to be used where transverse construction or
contraction joint occurs. Shall be used where a
longitudinaL construction joint intersects with a joint
in the Plastiline.
Normal jointing method C3
Apply welding strip after stripping formwork
Plastiline
Method of jointing sheet, except where construction or
contraction joint occurs, should be used when longitudinal
construction joint intersects with a joint in the Plastiline.
Shall not be used where transverse construction or
contraction joint occurs.
13

9.5 A liner return shall be provided at the junction of a
structure with an adjacent unlined structure or concrete
pipe. This return shall be made as follows:
Each liner return shall be a separate strip of liner at least
75mm wide jointed at right angles to the main liner by
means of approved corner strips.
Corner strips shall be welded continuously to the return and
to the main liner and applied wherever possible from the
back of the lining.
Locking extensions shall be provided on returns to lock the
returns to the concrete of lined, cast-in-place structures.
Each liner return shall be sealed to adjacent construction
with which it is in contact by means of a compound
recommended by Humes.
Corner joint internal — D1
Corner joint external — D2
Note: All joints to be covered with PVC tape after
attaching sheets, angles and corners to formwork to prevent
grout leakage.
Radiused corners
It is recommended that where possible all corners be
radiused as shown so that the sheet is continuous around
the corner.
25mm min.
Radius
25mm min.
Radius
9.6 Where specified, non-skid surfaces are to be installed
by welding flat welding strips, at 100mm centres, to the
surface of the Plastiline. A less durable alternative would
be to bond a clean, well-graded sand to the surface of
the lining with adhesive. The materials used and technique
employed are to be in accordance with the Humes’
instructions.
Prior to placing the reinforcement, the lining shall be
checked to ensure that it is free from wrinkles and bulges,
and is securely held so that it will not move during
subsequent operations. Care shall be taken to prevent
damage to the sheet at all stages.
9.7 All joints between sheets and/or blankets which will
have to be welded after stripping the formwork must be
covered by PVC tape before casting to prevent grout
penetration behind the sheet.
The concrete shall be placed and compacted in such a
manner as to produce a dense homogeneous concrete
securely anchoring the locking keys in place, and at the
same time avoiding damage to the Plastiline.
After curing, the forms are to be removed in such a
manner as to prevent damage to the lining. Sharp tools
must not be used to pry forms from lined surfaces.
Any tears, abrasions or cuts are to be marked for
subsequent repair.
If steel bands are used for securing the lining, they must be
cut back to the surface of the concrete after stripping.
9.8 Field joining of the lining can be carried out at any
time after the structure has been cured and accepted by the
client’s representative.
The Plastiline must be clean, completely free of
concrete or mortar and other foreign matter and must be
dry at the time of application of the welding strip.
Under no circumstances must sewage or waste enter the
structure until all field welding is completed and all testing
carried out.
All field welding shall be carried out by qualified welders as
specified in Clause 8.4 of these specifications.
9.9 Inspection, Testing and Repair
All welds including any repairs shall be subject to the
inspection and testing as laid down in Clause 11.
14

10 Jointing of precast products
(including pipes) lined with Plastiline to
insitu structures
10.1 Where a product lined with Plastiline is to be joined
to an unlined insitu structure a liner return shall be made as
follows:
The lining is cut off flush with the end of the product and
an end cap is fabricated to cover the end, and form a
50mm (minimum) return on the outside surface.
The end cap is not keyed to the product and plain PVC
sheet is used. The annular shape to cover the end may be
formed from several pieces butted together with a gap less
than 4mm, and may be held in place by an approved
adhesive for welding. Outside corner weld strip is used to
join the annular shape to the lining and to the return. Any
butt joints are sealed with flat welding strip.
10.2 Where a product lined with Plastiline joins a lined
insitu structure the joint shall be constructed by one of the
following methods:
a) Where the product is to be connected after the
insitu structure has been constructed, a hole should be cut
or formed in the structure and the joint made using an
approved method.
The joint protection is then provided by using a piece of
plain sheet with a central hole cut to fit the interior of the
product. This also overlaps the surrounding insitu lining by
50mm (minimum) to 200mm (maximum). The plain sheet
may be made up from several pieces. It is welded to the
product lining using outside corner welding strip and to the
insitu lining using flat welding strip.
b) If the end of the product is to be cast into the insitu
structure the keys on the lining fitted to the inside
formwork should be cut off at the joint position and the
lining trimmed off flush with the end of the product, which
is then placed in position and held against the insitu lining
during the pouring of the structure. After removal of the
formwork the insitu lining is cut away flush with the
interior of the product and welded to the precast product
lining using outside corner strip.
10.3 All field welds, and any repairs carried out in the field
shall be subject to the inspection and testing
specified in Clause 11.
Precast access chamber base with benching.
2100mm Plastiline pipe with an opening for a manhole take off.
15

Jointing details — pipes to insitu structures
Joints to UNLINED insitu structures
Pipe fitted to preformed hole — D5
Plastiline end cap fabricated from plain sheet, cut to shape
and welded over end of pipe prior to fixing pipe in place
Joints to LINED insitu structures
Pipe fitted to preformed hole — D7
Details of seal between pipe lining and the insitu structure
Pipe cast into structure — D8
Details of lining seal when pipe is cast into structure
16

11 Testing
11.1 Prior to conducting tests listed in this section, careful
inspection shall be made for visible damage and faulty
welding. After joint welding of blankets in pipelines and
structures, all welds shall be subjected to the tests
specified in this section.
11.2 Particular attention must be given to weld beads on
both sides of weld strips (see illustration). After welding,
beads should be visible on both sides of the weld strip.
The weld must be checked by probing the fillet area with a
well worn (i.e. no sharp edges) screwdriver blade. At any
place where the probe indicates a weak weld, or enters
more than 3mm, a reweld shall be made in
accordance with the procedure specified in Clauses 12.6
and 12.7 of this specification. If overheating has occurred
during welding the evidence is charring at the edge of the
strip. All charred sections must be replaced.
11.3 If required by the client, the lined surface shall be
100% spark tested using an approved spark tester and
brush with a potential of at least 10,000 volts. Two
alternative methods of positively testing joints and
patches are the vacuum box method for flat areas such as
tanks, and the pipe weld tester for pipelines. Both the
vacuum box and pipe weld tester must be of an approved
design. If the vacuum box is used as a means of testing,
Humes should be consulted as special design characteristics
assist in testing by this method.
Defective areas found by these tests must be repaired as
per Section 12 and subsequently retested.
11.4 Where required by the client, a pull test can be
performed to check that proper embedment of keys has
been achieved. A direct pull is applied normal to the
concrete surface, on a cut section of the embedded sheet
containing a single embedded key 100mm to 200mm long.
The concrete should be fully cured and the key shall
withstand the specified pull of 14 N/mm without rupture of
the concrete or the key, or withdrawal of the key from
the concrete. Strictly the test should be made at a
temperature between 10 O C and 27 O C and at least 14 days
after embedment. Refer to Humes if full details are
required.
11.5 Where large areas of lining are involved, testing must
be carried out progressively as the work proceeds to avoid
accumulation of defects from faulty workmanship which
could have been detected and corrected at an early stage.
Spark testing may not detect faults in welds or where
sheets overlap, and must be supplemented by the other
procedures described above in order to ensure sound
workmanship in these areas.
Plastiline spark testing.
17

12 Repairs
12.1 Any areas revealed as defective shall be repaired in
accordance with the following clauses.
12.2 For isolated pinholes or for straight cuts and tears
where the cut or torn edges can be brought together, the
repair is made by welding flat welding strip over these
areas, taking care that it is centrally located.
12.3 Damaged sections equivalent in area to about 40,000
mm 2 which cannot be repaired by the method
described in Clause 12.2 shall be treated as follows.
The defective area of the sheet is to be cut, preferably to a
rectangular shape, and removed. A piece of plain
Plastiline sheet cut to shape is tack welded in place, or
fixed with adhesive in the opening of the sheet, leaving no
gap greater than 4mm. The gaps are then sealed by
welding centrally located flat welding strips over them.
Alternatively the plain Plastiline patch may be cut
larger than the defective area by at least 12mm all round,
the edges chamfered and the patch sealed with flat
welding strip.
12.4 Where damage covers an area greater than
40,000mm 2 but a patch not greater than 100mm in width
can be used to effect the repair, the methods described in
Clause 12.3 shall be used.
12.5 Plastiline damaged over an area greater than
40,000mm 2 during handling and laying of a pipe, may be
repaired at the discretion of the Supervising Authority.
The repair would be at the expense of the contractor (refer
Humes for specialised procedure).
12.6 Where brittle field welds occur due to overheating or
charring, the defective area must be cut out and patched
with plain Plastiline sheet as described in Clause 12.3.
Where the existing weld strip interferes with the new
welding, the operation is completed by carefully heating
the plastic junctions until they are soft and can be
worked together.
12.7 Short lengths, less than about 25mm individually, and
not more than 250mm in any one metre of weld, where the
probe will enter more than 3mm under the edge of the
weld strip, are classified as short incomplete welds.
(Occurrence of frequent short incomplete welds is general
evidence of substandard welding.) These faults may be
corrected by lifting up the unsealed edge with a blunt knife,
carefully directing the heat into the opening and pressing
the strip down firmly.
12.8 Where incomplete welds longer than specified in
Clause 12.7 occur, they are to be treated by the methods
described in Clause 12.6.
12.9 All repair operations must be subjected to the same
stringent control as stipulated for joint welding. Upon
completion of repair work, all tests and inspections laid
down in Section 11 must be performed again and restored
areas spark tested.
13 Handling — storage — laying
13.1 Proper handling and welding of plastic lining is
primarily a matter of care and common sense. Personnel
must be aware that in the manufacture of Plastiline and
its application to concrete pipes, careful control is exercised.
This care is nullified if the material is subsequently damaged
by carelessness and faulty practices. Failure to carry out
simple precautions against damage cancels the customer’s
investment in protection.
13.2 Personnel must have the clear understanding that
after jointing, the Plastiline must form a continuous sheet
lining (i.e. free of pinholes, cuts, burns, abrasions)
throughout the length of the pipeline.
Personnel should have theoretical and practical basic
training in welding of plastics.
Plastiline welding repairs.
18

13.3 During loading, transporting, unloading and laying of
lined concrete pipe, proper protection must be given to the
Plastiline to prevent tears or punctures. Preferably, all
lifting and transporting gear shall operate against the
external surface of the pipe. If internal lifting gear is used,
rubber or equivalent pads must be provided to protect the
Plastiline. Under no circumstances will hooks or other
sharp edged and pointed lifting devices be used.
13.4 The projecting flap at the spigot end of the pipe
requires special attention, both during handling and the
actual laying operation. Damage can be caused by
handling equipment or contact with another pipe.
The flap must not be subjected to excessive tension and
distortion (particularly in cold weather) by bending it back
sharply at the end of the pipe, and it must enter the socket
of the adjacent pipe cleanly.
13.5 As soon after delivery as possible representatives
of the laying contractor and Humes will inspect the pipes
in accordance with Section 11 of this Specification. Any
damage found subsequent to this inspection will be deemed
to be due to the contractor’s mishandling and repaired or
rejected at his expense in accordance with Section 12 of this
Specification.
13.6 Attention must be given to sources of damage liable
to occur during handling and laying but particularly
applicable during storage. Apart from recommendations
cited in Clauses 13.3 and 13.4, precautions must be taken
to obviate damage likely from:
(a) Materials carried or stored inside the pipe.
(b) Footware of workers (especially if they use the pipe as
shelter during wet weather).
(c) Excessive heat (blow lamps).
(d) Vandalism.
13.7 During normal pipe laying procedure, the following
bad practices must be avoided:
(a) Damage to spigot flap caused by contact with
another pipe or failure to correctly position the flap
into the adjacent pipe.
(b) Sharp changes in direction of the sheeting at the
joint due to foreign matter under either or both edges
of the plastic lining or excessive mortar in any
mortared-up gap.
(c) Incorrect positioning of the invert gap. Pipes with
circular reinforcements shall be laid with the centre
line of the invert gap and the centre line of the final
pipe line in the same vertical plane. Pipes with
elliptic reinforcements will have their ‘TOP’ marked
at the factory.
(d) Damage to the Plastiline by misuse of toms and
other types of winch anchors.
13.8 Plastiline sheet for use in insitu linings must be
prepared on a surface free of rocks, stumps and other
protrusions which may cause tears or punctures in
subsequent handling of the sheet. The area selected is to be
free from all types of construction traffic, and is to be of
sufficient area to facilitate handling of the sheets which are
cut to size prior to the placement of the sheets onto
the formwork.
13.9 The joining of the Plastiline can be carried out at
any time after the pipes have been laid, and preferably
before backfilling and line testing, if any. If the spigot flap
has been bent back to allow jointing, it must be released for
a sufficient period of time prior to jointing to allow it to
return to its original position.
13.10 The Plastiline must be clean, completely free of
mortar and other foreign material, and must be dry at
the time of application of the welding strip. The cleaning
agent Applied Chemicals 4480 or approved equivalent is
recommended for surface cleaning.
13.11 Under no circumstances must sewage or waste be
discharged through pipes or structures lined with
Plastiline until all field welding is completed and all
testing carried out. Any failure to do this will endanger the
client’s investment in protection.
14 Periodical inspections
14.1 Although Plastiline is tough and abrasion resistant,
it can be damaged by sharp edged impact (such as would
be caused by sharp metal objects which may find their way
into the sewer).
14.2 Damage is detected by physically inspecting lines
and structures at low flow. Where conditions are
particularly severe, inspections should be carried out at
appropriate intervals by the authority. This could be as
short as two years but should never be longer than five
years. These inspections are the responsibility of the client
Authority but Humes will give advice if possible when
requested to do so.
14.3 Minor damage such as small punctures will
eventually become obvious as a bulge caused by
aggressives passing through the hole and attacking the
concrete behind the lining. This is not serious and is easily
repaired by cutting away the sheet to expose the affected
concrete, which should be cleaned before repairing as in
Clause 12.2.
Barwon Water Outfall Sewer (above) has exhibited far less
build-up of slime and solids on the Plastiline than would
normally occur on a concrete pipe surface. This line is operating
satisfactorily after 35 years of service.
19

Major Projects
EXPRESSWAY, SOUTHERN AUSTRALIA
PERTH MAIN SEWER, WESTERN AUSTRALIA
EASTERN DISTRIBUTOR, NEW SOUTH WALES
SMELTERS PRECAST ELEMENTS, NORTHERN AUSTRALIA
DRAINAGE, SOUTH EAST QUEENSLAND
For further information please contact your nearest Humes office:
HEAD OFFICE
18 Little Cribb Street,
Milton. QLD 4064.
Tel: (07) 3364 2800 Fax: (07) 3364 2963
NORTH QUEENSLAND
Ingham Road,
Bohle. QLD 4818.
Tel: 1300 361 601 Fax: (07) 4758 6001
CENTRAL QUEENSLAND
MacLaughlin Street,
Rockhampton. QLD 4701.
Tel: 1300 361 601 Fax: (07) 4926 1837
SOUTH EAST QUEENSLAND
59 Sugarmill Road,
Meeandah. QLD 4008.
Tel: 1300 361 601 Fax: (07) 3866 7101
NEW SOUTH WALES
Cnr Woodstock Ave & Glendenning Road,
Rooty Hill. NSW 2766.
Tel: 1300 361 601 Fax: (02) 9625 5200
NORTH WEST NEW SOUTH WALES
Showground Road,
Tamworth. NSW 2340.
Tel: 1300 361 601 Fax: (02) 6765 2683
VICTORIA
122a Doherty’s Road,
Laverton North. VIC 3028.
Tel: 1300 361 601 Fax: (03) 9360 3887
TASMANIA
19-25 Churchill Park Drive,
Invermay. TAS 7248.
Tel: 1300 361 601 Fax: (03) 6335 6330
SOUTH AUSTRALIA
39-43 Maxwell Road,
Pooraka. SA 5095.
Tel: 1300 361 601 Fax: (08) 8349 4992
WESTERN AUSTRALIA
36-38 Felspar Street,
Welshpool. WA 6106.
Tel: 1300 361 601 Fax: (08) 9351 6977
NORTHERN TERRITORY
1606 Reichardt Road,
Winnellie. NT 0821.
Tel: 1300 361 601 Fax: (08) 8947 0535
Visit our website: www.humes.com.au
© Copyright Humes 2003. ABN 87 099 732 297 G40HUMB100 05/03