Hats off to you! You’ve battled through the design phase, wrestled with geotechnical reports, and hammered out a solid plan for a state-of-the-art PSH reservoir. You’ve got the strategy, the specs, and the material science all lined up. But as every seasoned field commander knows, the most brilliant battle plan is only as good as its execution.
In fact, not to put too fine a point on it, but this moment is where the whole project can fall apart. It’s the classic “for want of a nail” scenario—a single poorly handled panel, a careless mistake during welding, or a missed step in quality control can undermine the integrity of the entire multi-million dollar system. All that brilliant engineering work becomes irrelevant if the boots-on-the-ground execution isn’t flawless.
So over the next 2 chapters, we’ll cover this process from an entirely practical standpoint: from the logistics of getting massive RPE panels to the site, through the techniques for safe deployment and proper field seaming, and concluding with the critical quality assurance steps required to verify a leak-free installation. Let’s go.
Starting Off Right: Logistics and Material Handling
The first (deceptively simple) challenge in any large RPE liner installation is getting the material to the site and handling it correctly once it arrives. These are massive, multi-ton panels that require careful planning and the right equipment, and there’s no muscling them around if one gets placed crooked. An apparently innocuous mistake, even early in the game, can trigger expensive delays or damage the liner before it’s even deployed.
Shipping and Offloading
Your liner panels will typically arrive rolled or accordion-folded on flatbed trucks.
Coordination is Key
Work closely with your fabricator and trucking company to coordinate delivery schedules. You need to ensure you have the right equipment (usually a crane or large forklift with spreader bars) and sufficient personnel ready on site before the truck arrives. Delays at this stage cost money.
Inspect on Arrival
Before signing off on the delivery, visually inspect each panel for shipping damage. If you see tears or significant abrasions, document them immediately and notify the fabricator.
Safe Offloading
Use appropriate rigging, spreader bars, and soft slings to lift the panels (not drag them). Never use chains or hooks directly on the liner material, as they can easily abrade or puncture the liner.
On-Site Storage
Ideally, you’ll deploy panels shortly after they arrive. If storage is necessary, follow these guidelines:
Choose a Smooth, Level Area
Store panels on a clean, dry, and level surface away from heavy construction traffic. The ground should be free of sharp rocks or debris.
Protect from Damage
Keep panels covered with a sacrificial tarp if they will be stored outdoors for an extended period, especially in harsh weather or high UV conditions. Prevent equipment or vehicles from driving over or parking on the stored panels.
TLDR:
Treat the liner panels with the respect they deserve from the moment they arrive. A small amount of care during handling prevents big headaches down the road.
Deployment Techniques: Unrolling the Panels
Now you’ve reached the tricky part: you need to get those massive sheets unfolded and into position without damage to your liner (or your crew). Make no mistake: you’re not rolling out carpet; handling multi-ton, acre-sized panels takes a solid plan, the right gear, and a crew that knows what they’re doing.
Have a Plan, Walk the Plan
Remember that panel layout drawing your fabricator provided? That’s your map. Before hooking up a single strap, walk the site with your crew foreman and use the map to pinpoint where each panel starts and which way it needs to be pulled. Make sure to eyeball any potential hang-ups—a soft spot, a stray rock, anything at all. If you can get everyone on the same page before things start moving, you’re already halfway through the battle.
Gear Up Right
Unless you’ve got a team of Incredible Hulks on payroll, you’re not moving these things by hand. So it’s time to rely on some mechanical muscle:
Core Bar and Spreader
Most big panels come folded on a core pipe. You’ll need a spreader bar hooked to an excavator or crane to lift it safely. This lets the panel unfold smoothly as you pull.
The Right Pulling Gear
You’ll likely use an excavator or dozer for the main pull, especially going uphill. Use heavy-duty soft straps or specialized liner clamps. Whatever you do, don’t hook chains or metal directly to the liner. That’s just asking for a rip.
Ground Crew
You’ll need enough hands on the ground to guide the panel, keep the folds from bunching up, and yell “Stop!” if it starts snagging.
Field Smarts
Watch the Wind
That old proverb applies here: you really can’t fight Mother Nature. Trying to deploy a giant sail in a 20-mph wind is a recipe for disaster, so make note: if it’s blowing hard, wait it out.
Final Sweep
Just before you pull, have someone walk the path one last time. It’s amazing how often rocks or debris can appear out of nowhere.
Slow is Smooth
Easy does it on the pull. Avoid yanking or dragging the material too quickly. If it starts to wander off track, don’t try to strongarm it back into place. Just stop, reset, and go again.
Weight it Down
Once a panel’s in place, especially on a slope, scatter some sandbags or old tires across it. Trust us on this: a sudden gust of wind can lift an unsecured panel and make a real mess.
TLDR: Deployment is a big operation that takes coordination. Take your time, stick to the plan, and keep your eyes on protecting that liner.
