Rausch QuickLock User manual

Rausch Electronics USA, LLC. 4757 Innovation Way Chambersburg, PA 17201
Service: [phone] | Office: [phone] | Fax: [phone] | www.rauschusa.com | [email protected]
Operator Manual
QuickLock Operator Manual –Version 15.07.01
QuickLock is NSF/ANSI 61 Certified for use in potable water.
QuickLock meets ASTM Standard F3110-14.

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QuickLock Operator Manual –Version 15.07.01
IMPORTANT DISCLAIMER:
This manual is subject to change without notice. Updates can be obtained online at
www.rauschusa.com/quicklock. This manual does not guarantee the product will work
properly. The manual cannot take the place of your own experience or practical instruction by
the manufacturer. Contact a RAUSCH Certified Installer to ensure proper installation. The
following are important disclaimers to consider before using the QuickLock system.
1. QuickLock installations are to be performed only by trained and qualified personnel, using
adequate and safe equipment.
2. Read and follow the instructions, as described in this manual before attempting installation.
3. Prior to beginning the installation, verify that all the equipment and components involved are
undamaged and in proper working condition.
4. The use of equipment other than a certified Rausch packer and components will void the
functionality warranty. Using a Rausch QuickLock packer for non-OEM installations/sleeves
risks damages to the device or potentially injuring the operator, and voids all product
warranties.
5. Pressure gaugemust have the proper range setting (0 –70psi).
6. NEVER exceed the maximum packer pressure as indicated in the manual.
7. NEVER inflate the packer outside of a pipe –serious bodily injury or death may occur!
8. QuickLock is designed for and must only be used in municipal sewer, storm sewer and potable
water environment. For use in potable water, a special rubber gasket is required. For all other
applications, please consult Rausch prior to use.
9. Do not use QuickLock in broken pipes with protruding objects.
10. Verification of lines inner diameter / I.D. must be known as accurate as possible in order to
ensure the correct sleeve is used. Refer to the Data Sheet at the end of this manual.
11. If after reading this manual you have any questions or concerns, please contact Rausch USA.

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QuickLock Operator Manual –Version 15.07.01
Table of Contents
IMPORTANT DISCLAIMER:........................................................................................2
1. Description of the QuickLock System ................................................................5
1.1. Intended Use............................................................................................................. 5
1.2. Regulations............................................................................................................... 5
1.3. Certifications ............................................................................................................ 5
1.4. Components and functions ..................................................................................... 6
1.4.1. Stainless steel sleeve.............................................................................................. 6
1.4.2. Rubber gasket......................................................................................................... 6
1.5. Description of the system and installation procedure........................................... 7
1.6. Suitability and materials used................................................................................. 8
1.6.1. Properties of the pipe to be repaired........................................................................ 8
1.6.2. 316L Stainless Steel................................................................................................ 8
1.6.3. EPDM Rubber ......................................................................................................... 8
1.6.4. Industrial Use .......................................................................................................... 8
1.6.5. Types of Pipe Damages........................................................................................... 9
1.6.6. Durability................................................................................................................. 9
2. How to Install QuickLock...................................................................................10
2.1. Preparation ..............................................................................................................10
2.1.1. Pipe Inspection.......................................................................................................10
2.1.2. Pipe Preparation.....................................................................................................10
2.1.3. Space required by the packer.................................................................................11
2.2. Equipment, Material and Preparations for the QuickLock Installation................12
2.2.1. Equipment..............................................................................................................12
2.2.2. Material ..................................................................................................................12
2.3. Selecting the QuickLock Sleeve.............................................................................13
2.3.1. With beveled end....................................................................................................13
2.3.2. Without beveled end...............................................................................................13
2.4. Preparing the QuickLock sleeve ............................................................................14
2.4.1. Setup & Inspection .................................................................................................14
2.4.2. Lubricating the sleeve.............................................................................................14
2.4.3. Cutting the transportation tapes..............................................................................14
2.4.4. Apply talcum powder to the rubber gasket..............................................................15
2.4.5. Slipping on the rubber gasket.................................................................................15
2.4.6. Trimming (if necessary)..........................................................................................15
2.4.7. Centering the rubber gasket...................................................................................16
2.4.8. Affixing the rubber gasket.......................................................................................16
2.5. QuickLock Installation.............................................................................................17
2.5.1. The Packer.............................................................................................................17
2.5.2. Positioning the QuickLock sleeve on the packer.....................................................18
2.5.2.1. Standard Packer - Putting on the wheels......................................................18
2.5.2.2. Adjustable Packer –set to nominal diameter................................................18
2.5.2.3. Aligning the sleeve on the packer .................................................................18
2.5.2.4. Laser alignment............................................................................................18

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2.5.2.5. Aligning the locking gear strip.......................................................................19
2.5.2.6. Charging Device to hold position in place .....................................................19
2.5.3. Single Installation Procedure..................................................................................20
2.5.3.1. In the manhole..............................................................................................20
2.5.3.2. Positioning the packer & sleeve....................................................................21
2.5.3.3. Positioning Pressure.....................................................................................21
2.5.3.4. Deflating & Aligning in Center.......................................................................22
2.5.3.5. Align in Middle ..............................................................................................22
2.5.3.6. Application Pressure.....................................................................................22
2.5.3.7. Inspection.....................................................................................................22
2.5.4. Serial Installation (Standard Procedure).................................................................23
2.5.4.1. Procedure Overview .....................................................................................23
2.5.4.2. Installation ....................................................................................................24
2.5.4.3. Passing through the projecting rubber end....................................................27
2.5.4.4. The correct metal overlap .............................................................................27
2.5.5. Serial Installation (Alternative Procedure)...............................................................28
2.5.6. Using the Laser Marker..........................................................................................30
2.6. Special Scenarios....................................................................................................31
2.6.1. Repairing joint offsets.............................................................................................31
2.6.2. Groundwater infiltration ..........................................................................................32
2.6.3. Root penetration.....................................................................................................33
2.6.4. Corroded steel in reinforced concrete.....................................................................34
2.6.5. Repairing plastic pipes ...........................................................................................35
2.6.6. QuickLock in non-permeable pipe systems ............................................................36
2.6.7. Using QuickLock to repair holes longer than single sleeve.....................................37
2.6.8. Removing installed QuickLock sleeves...................................................................38
2.6.9. Deflating the packer using a vent valve ..................................................................39
3. QuickLock Technical Data Sheet......................................................................40
4. QuickLock Wheel Set Charts ............................................................................42
5. QuickLock Adjustable Packer...........................................................................48
5.1. Description...............................................................................................................48
5.2. Operation.................................................................................................................48
5.2.1. Setting compressed air supply................................................................................48
5.2.2. Remove the wheel..................................................................................................48
5.2.3. Adjust the slide.......................................................................................................48
5.2.4. Insert the wheel......................................................................................................49
6. Table of Application Pressures.........................................................................50

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1. Description of the QuickLock System
1.1. Intended Use
QuickLock is an entirely mechanical, seamless assembly system for patch repairs
inside pipes ranging from 6” to 32”pipe diameter in any common wastewater, well,
or drinking water pipe system.
A perforated version is available for stabilizing drainage pipes.
1.2. Regulations
The basis and general specification for pipe repairs using the Quick-Lock system is
DWA data sheet M143 Part 5
“Repairing wastewater pipes and sewers with internal sleeves”
1.3. Certifications
The QuickLock system for pipe diameters 6” –28”:
Has been certified under building law by the German Institute for Civil Engineering (DIBt) since
2005.
The system is also certified as resistant to jetting in accordance with DIN 19523.
Meets ASTM F3110-14 Standard Practice for Proper Use of Mechanical Trenchless Point Repair
Sleeve with Locking Gear Mechanism for Pipes of Varying Inner Diameter and Offset Joints
NSF/ANSI 61 certified for use in potable water.
For pipe diameters from 6” to 24”, there is a structural standard for host pipe state II, based on a
hydrostatic water pressure of 7.25 psi (0.5 bar) and twofold structural safety.

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1.4. Components and functions
1.4.1. Stainless steel sleeve
1- Beveled End
The beveled end faces the direction of
flow and improves the hydrodynamics,
prevents solids from depositing, and
increases jetting resistance.
2- Metal Overlap
The steel sleeve is rolled up smaller
than its nominal diameter. The overlap
is what is left over for expanding to
the pipe wall.
3- Toothed Strip
The locks that keep the sleeve
expanded run along the toothed strip.
4- Lock
The lock is a small set of gears that only
moves in one direction, thus keeping the
sleeve expanded.
5- Adhesive Tape
The tapes are put on at the factory to
protect the sleeve during the transport and
prevent it from unrolling.
6- Plastic Rivet
The plastic rivet prevents the sleeve from
unrolling and is sheared off during inflation.
1.4.2. Rubber gasket
7- Circumferential seals
The actual seal is formed by the
circumferential seals compressed
against the host pipe. The
damaged section must always be
between these seals.
8- Trimming Line
There is a trimming line marked in
the rubber gasket. It shows you
where to cut off the projecting
rubber end (when a single sleeve
is installed).
9- Projecting Rubber End
The projecting rubber end acts as
a seals between sleeves installed
in a series.
Cross section of steel sleeve and rubber gasket.

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1.5. Description of the system and installation procedure
QuickLock consists of:
A rolled up 316L stainless steel sleeve
A rubber gasket
The damaged section is repaired and sealed
by permanently clamping the steel sleeve in
place.
This exerts a pressing force which compresses
the rubber gasket against the inside of the
pipe.
The area between the circumferential seals (1)
is completely sealed.
When the steel sleeve is manufactured, it is rolled
tighter than the diameter of the pipe to be repaired.
Two toothed strips are punched into the sleeve, on the
left and right.
In each toothed strip there is a lock.
The lock is for clamping the steel sleeve.
The lock can only move in one direction and
stops the sleeve from contracting once it has
been expanded.
The lock moves along the toothed strip (to the left as
shown here).
This means that the steel sleeve can only expand in
one direction.
The lock prevents it from contracting again.
The increments are only 0.65 mm (.025”), which
means that the sleeve is almost infinitely adjustable.
How it works: The middle gear wheel is on a spring
and acts as a ratchet for the others.

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1.6. Suitability and materials used
1.6.1. Properties of the pipe to be repaired
QuickLock can be used to repair all common types of pipe:
Vitrified clay pipes
Concrete pipes
Plastic pipes (see section 2.6.5)
Glass-reinforced plastic pipes
Cast iron pipes
Steel pipes
QuickLock is only suitable with restrictions in the following cases:
Pipes with bends and fittings
Pipes with damage near the building connections (sockets, branches)
Pipes with joint misalignments of more than 2.5 cm (0.98”)
In such cases, please contact us.
1.6.2. 316L Stainless Steel
The QuickLock sleeve is made of 316L stainless steel of grade 1.4404. This grade of stainless steel is
characterized by its high corrosion resistance.
Quick-Lock is designed for use in municipal wastewater systems.
For use with industrial wastewater or where the wastewater contains high levels of chloride salts,
the required corrosion resistance must be ascertained.
316L stainless steel of grade 1.4404 may be used up to a chloride concentration of 600 mg/l.
1.6.3. EPDM Rubber
Like the steel sleeve, the thermoset polymer EPDM gasket is designed for municipal wastewater systems.
EPDM is characterized by its excellent physical properties and its resistance to aging, ozone, weathering
and environmental effects, alkalis, and various chemicals.
EPDM is unsuitable, or only suitable with restrictions for:
Solvents
Ethers, esters, ketones, methylene chloride
Animal and vegetable fats, oils, fuels
Concentrated fruit juice, oxidizing acids
Special version for oils, greases and hydrocarbons
An NBR rubber gasket is available on request for use with oils, greases, and hydrocarbons. (NBR: nitrile
butadiene rubber)
Special version for potable water.
A special NSF61 certified rubber gasket is required for potable water installations. Available on request.
1.6.4. Industrial Use
QuickLock is also suitable, with certain restrictions, for industrial use, depending on the properties of the
fluids.
Note: Before using QuickLock in industrial, non-municipal wastewater systems, the corrosion resistance
of the 316L stainless steel and the EPDM gasket must be verified.

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1.6.5. Types of Pipe Damages
Crack formation (longitudinal, radial and transverse)
Fragmentation
Leaking joints
Displacement / joint offset
Closing/sealing dormant unused laterals
Corrosion/ bursting / wear (reinforced concrete pipes with exposed reinforcement)
Leaks (ground-water infiltration and exfiltration)
Improvement of the structural strength of pipes (cracks and fragmentation, deformations)
Root penetration
Length of damage
When installed individually, QuickLock can be used for instances of damage up to the following lengths:
6” – 16”: maximum damage length 10.62”- 11.81” (see Technical Data Sheet, sealed area)
18” – 32”: maximum damage length 11.02” – 13.38” (see Technical Data Sheet, sealed area)
Instances of damage that are longer than this can be repaired by installing multiple sleeves in a series.
1.6.6. Durability
QuickLock repairs are extremely durable.
The materials used –stainless steel and EPDM –have proven their worth in municipal wastewater
systems for decades. A service life of more than 50 years can be expected.
Compound cracks,
fragmentation,
weakened pipe
Water ingress
Root
penetration
Leaking
joints
Unused
laterals
Joint Offset

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2. How to Install QuickLock
2.1. Preparation
2.1.1. Pipe Inspection
Before using QuickLock, the pipe must be inspected to ascertain whether it can be repaired with the
system.
There must be at least one access via a manhole or inspection chamber.
The accessible manhole should have a diameter of at least 24 inch, in order to properly ensure
setting up the camera/tractor system and the QuickLock installation packer.
2.1.2. Pipe Preparation
Prior to installing the QuickLock system, the pipe must be cleaned by using a high-pressure jetter.
Hardened deposits, root infiltration, connection sockets protruding into the pipe must be
removed by means of suitable milling or cutting tools.
The pipe must be free of obstacles that could prevent the packer from traveling through.
The section of pipe to be repaired must be free of all solids such as sand and gravel, hardened
deposits, or wastewater solids.
Joint offsets larger than 0.39 inches must be milled off, if only a single sleeve is to be installed.
If (2) sleeves are available, a different installation method can be chosen. (See 2.3.3)
As a general rule, the QuickLock repair work can be completed during normal sewer operation,
however, the flow-level should be no more than approx. 20% of the sewer’s cross section. If too
many foreign objects are washed-in during the repair process, this pipe will need closed off and
by-passed - just to play it safe.
Notes for Nominal Diameter 28” & 32”
When using the QuickLock 28” sleeve, the top rungs in the manhole have to be removed.
The QuickLock 32” sleeve will not fit through a 24.5” manhole entrance – rolled up, its diameter is 27.36”.
The cone section of the manhole must be removed.
Depending on the type of damage, the QuickLock BIG 32” sleeve, which comes in two sections,
can be used.