Project Overview
A large industrial processing facility required rehabilitation of a critical underground piping system carrying a combination of stormwater and process sewer flows. The existing infrastructure – comprised of aging vitrified clay (VCP) and reinforced concrete pipe (RCP) – was experiencing severe infiltration, structural deterioration, and chemical corrosion.
The effluent within the system was both chemically aggressive and elevated in temperature, with ongoing pH-balancing treatments accelerating pipe degradation. At the same time, the facility required continuous operation, making traditional excavation or disruptive pipe repair methods impractical.
NuFlow Indy was selected as the contractor to deliver a trenchless pipe rehabilitation solution capable of restoring structural integrity while withstanding these demanding conditions – without interrupting operations.
The Solution: UV-Cured CIPP with Trelleborg Mainline
After evaluating the system and environmental factors, NuFlow Indy identified UV-cured CIPP (Cured-In-Place Pipe) with pre-impregnated glass-reinforced plastic (GRP) liners as the optimal rehabilitation method. The liner system was specifically selected to handle elevated temperatures and chemical exposure, ensuring long-term durability in a highly aggressive environment.
To execute the project, NuFlow Indy deployed the Trelleborg Mainline UV PowerLight Pro system, designed for high-performance mainline rehabilitation across a wide range of pipe diameters.
Key Advantages of the System
- Wide diameter capability, supporting installations up to 72 inches
- Controlled UV curing for consistent, high-quality liner installation
- Integrated KAESER blower enabling rapid liner inflation and precise internal pressure control
- Scalable platform adaptable across industrial and municipal pipe rehabilitation applications
These features allowed NuFlow Indy to confidently take on the project and scale as additional pipeline segments were added, ultimately totaling 1,826 linear feet of rehabilitated pipe ranging from 12 to 48 inches in diameter.
Project Execution
Installation began in November 2025 and was completed in March 2026, with NuFlow Indy performing all UV CIPP lining work while the facility remained fully operational and underwent concurrent infrastructure upgrades.
The project was executed in 16 controlled sections, requiring close coordination between NuFlow Indy, plant engineers, and supporting contractors. Each phase demanded careful management of flow rates, temperature, and chemical conditions to ensure successful installation.
Flow control was managed by R.H. Marlin, who worked in conjunction with plant operations to implement a system utilizing approximately 20 frac tanks and handling up to 420,000 gallons of process water per line. Continuous monitoring of flow and pH levels ensured stable conditions throughout the installation process.
This coordination allowed NuFlow Indy’s crew to remain focused on execution, delivering consistent results across varying pipe diameters and conditions.
Working in Challenging Conditions
The project environment presented ongoing challenges, including active industrial operations, aggressive effluent conditions, and extreme weather. A historic rainfall event during installation caused system surges and backflow into active work zones, requiring rapid adjustments in flow management and installation sequencing.
Despite these conditions, the combination of pre-impregnated GRP liners and the controlled curing process of the Trelleborg system enabled NuFlow Indy to maintain quality, consistency, and progress throughout the project.
Results
- 1,826 linear feet of pipe rehabilitated across 12”–48” diameters
- Structural restoration of a critical stormwater and process sewer system
- Liner system designed to withstand high temperatures and aggressive chemical exposure
- Zero unplanned downtime for the facility
- Successful execution in a complex, live industrial environment
Conclusion
This project demonstrates how UV-cured CIPP trenchless technology delivers a reliable solution for large-scale industrial pipe rehabilitation. In environments where heat, chemicals, and operational constraints demand precision and durability, selecting the right system is critical.
With the Trelleborg Mainline PowerLight Pro, NuFlow Indy was able to execute efficiently and effectively – delivering a controlled, high-performance installation under challenging conditions. The result is a long-term pipe rehabilitation solution that restores infrastructure while minimizing disruption, reinforcing the value of UV CIPP in demanding industrial applications.
Contact NuFlow Technologies today to discover how trenchless CIPP lining can restore your infrastructure, minimize disruption, and keep your operations running without interruption.
FAQ
- What is UV-cured CIPP and how is it different from traditional lining?
UV-cured CIPP uses pre-impregnated liners that are cured with ultraviolet light instead of heat or steam. This allows for faster installation, more controlled curing, and consistent liner quality—especially in large-diameter or complex systems. - Why was trenchless pipe rehabilitation necessary for this project?
The facility required continuous operation, making excavation or shutdown-based repairs impractical. Trenchless CIPP allowed the system to be restored without interrupting operations. - Can CIPP liners handle high temperatures and chemical exposure?
Yes. In this project, GRP liners were specifically selected for their ability to withstand aggressive chemicals and elevated temperatures common in industrial environments. - How do you manage flow during a live industrial pipe rehabilitation?
Flow control is handled using bypass systems, frac tanks, and continuous monitoring. This ensures stable conditions while allowing installation to proceed safely and efficiently. - How long does a large-scale industrial CIPP project take?
Timelines vary based on scope, but this project—covering over 1,800 linear feet—was completed over several months while maintaining full facility operations.
Today!