Technical Manual: Conduits through Embankment Dams (FEMA 484)

Appendix B—Case Historieshose and elbow, where it was turned inside out and securely fastened to the outsideof the elbow. A winch and roller were set up at the gate house doorway, and asecond roller was positioned at the bottom of the shaft. The tunnel surfaces wereswept clean, and utility lines (for lighting, ventilation, and water circulation) wereestablished within the shaft.The resin-filled tube was delivered to the site on August 11 in a refrigerated truck(figure B-80). The nonwoven fabric tube was manufactured in Houston, Texas atInLinerUSA headquarters, and the resin was added in Alma, Colorado at a “wet-out”plant used by WSU. Total weight of the liner was 10,000 pounds. The liner wasremoved from the refrigerated truck using a truck-mounted winch, and was carefullyfed into the tunnel at the downstream portal and slowly pulled upstream. The linerwas pulled into final position in the tunnel within about 1.5 hours and was securelyfastened to the steel elbow outside the calibration hose. Reservoir water from theupstream gate shaft was pumped into the water column to begin inversion of thecalibration hose under a 1-foot head. Within 20 minutes, the calibration hose hadbeen turned inside out and extended the full length of the liner, pressing the linertightly against the tunnel surface. Two perforated water supply hoses inside thecalibration hose were used to circulate heated water from a heat exchanger truckunder the full 12-foot head.Return water temperatures at the truck reached 135 °F in 2 hours and were heldconstant for 4 hours, and then were raised to 175 °F within 1 hour and were heldconstant for 6 hours for curing the resin. After curing was completed, the circulatingwater was gradually cooled to 100 °F in 4 hours, finishing by noon on August 12.Epoxy vinyl ester resin contains styrene, a possible carcinogen, which is releasedduring the curing process. Styrene vapors are heavier than air, and potentiallyflammable and explosive. Installers and inspectors must follow OSHA regulationspertaining to workers in hazardous and confined spaces. Fresh air had to beintroduced into the tunnel before the contractor could cut a small hole in the end ofthe hardened liner to release the water.The waste water was fully contained within the downstream stilling basin to permitfinal cooling to 70 °F, removal of resin residue from the water surface, anddissipation of dissolved styrene.Both ends of the liner were trimmed using chain saws and circular saws, and a0.5-inch deep groove was provided around the periphery to accommodateinstallation of end seals. Amex 10/WEKO seals were used, each consisting of a14.5-inch wide rubber seal with three stainless steel bands spread by a hydraulicexpanding device to ensure a tight fit. The work was completed on August 15, oneweek after site mobilization, for a total cost of about $145,000. Subsequentlaboratory tests on field samples confirmed the design parameters for tensile andflexural properties.B-115