Severe constraints are applied to sewerage, which may result in premature deterioration. These include root intrusion, joint displacement, cracks, and hole formations that lead to a significant volume of leakage with an overall risk for the environment and public health. For example, it is estimated that 500 million m3 of contaminated water per year can leak into soil and ground-water in Germany. The rehabilitation and replacement of damaged sewers is very costly. Annual rehabilitation costs for Los Angeles County are about €400 million, and in Germany, these costs are estimated to be €100 million.
Hydrogen sulfide (H2S) is indirectly responsible for
biogenic sulfide corrosion of iron sewers and consequently such sewers need rehabilitation work. Various repair options are available to owners over a large range of costs and potential durability. One option is the application of a cementitious material based on
calcium aluminate cement, after a cleaning of the corroded structure to remove loose material and contaminants in order to expose a sound, rough and clean substrate. Depending on the concrete condition and contamination, the cleaning can range from simple high pressure jet water cleaning (200 bar) up to real hydro-demolition (2000 bars). One method to ensure sound concrete is exposed is to verify that the surface pH is superior to 10. As for any concrete repair, the state-of-the-art rules must be followed. After this cleaning step, the cementitious material is applied to the saturated-surface-dry substrate using either: • Low pressure wet spray: this method is the more common because it does not produce dust and virtually no material is lost by rebound. It utilizes classical facade rotor pump, easily available in the market. The main drawback is the limited pumping distance that cannot exceed 75 meters. • Spinning head wet spray: this method is similar to the first, but the manual spraying is replaced by a spinning head projecting the mortar onto the repaired surface. This method is fast and especially suited for cylindrical chambers such as manholes. When a structure is so severely corroded that human entry is a risk, spinning head application permits an “un-manned” consolidation of the manhole. • High pressure dry spray: this method, also called “
shotcrete” or “gunite” is allowing a faster rate of rehabilitation, and also to make a thicker application in a single pass. The main interest of dry shotcrete is the capacity to pump the mortar over a long distance and this is needed when the access points are distant. Perhaps the longest dry
shotcrete distance is a job site in
Australia in 2014, where 100%
calcium aluminate mortar was air transported over 800 meters before being sprayed. The main drawback with dry shotcrete is the generation of dust and rebound; these could be limited and controlled with appropriate means (pre-moisture ring, adapted aggregate grading, experienced nozzleman, water mist cut-off walls, etc.). == Challenges ==