Presentation on theme: "NeoPoxy 50-Year Design Life Structures Using Traditional Materials"— Presentation transcript:
1NeoPoxy 50-Year Design Life Structures Using Traditional Materials David H. Johnson, NeoPoxy Corp.An engineering guidefor economicallong-life rehabilitationand protection.
2What Are The Problems? Hydrogen Sulfide/Sulfuric Acid Attack Reduced I&I is lowering flow ratesAcid generation is increasingDeterioration rate is rapidly increasingSystem investment is being lost
3What Are The Solutions? Cement relining Bag liners Mechanically locked PVCPolyurea & PolyurethanePureEpoxy Lining Systems
4Why Use A 50-Year PureEpoxy Structural Design? 34 Foot Structural Liner – One of 43 Manholes –Eliminate FailuresEnhances Host StructureDelivers Long-Term Value25-Year Proven Design50-Year Materials Experience
5Why Use PureEpoxy Liners? Monolithic ProtectionNo annulusImpervious to H2SUnaffected by Caustic or AcidASTM Design-Compliant
6Why Use An ASTM Design? 25-Year Reliability No Corrosion Failures No Structural FailuresConservative, Predictable & SafeASTM – An International Standard
7ASTM F1216 Wall Thickness Design P = groundwater loadk = enhacement factorEL = long term flexural modulusv = Poissons ratioSDR = standard dimensional ratioC = ovality reduction factorN = safety factorASTM F “Partially Deteriorated” Design FormulaThickness increases with loadEpoxy’s Recognized Bonding Characteristics Provides A Massive Safety Factor
8ASTM F1216 Wall Thickness vs.. Hydrostatic Load Partially Deteriorated DesignNPR-5300Wall thickness design increases from 0.25” after the water table is reached
9Typical 4’ ID Manhole Wall Thickness 0.25” (250 mils)Avg. Water TableIncreasing Thickness With Greater Load10’ of water= 0.44”20’ = of water 0.55”30’ = of water 0.63”
10Recognized Corrosion Resistance Requirements ASTM FCity of Los Angeles*10% Sulfuric Acid5% Nitric Acid10% Phosphoric AcidGasolineTap Water31% Sulfuric Acid**5% Sodium Hydroxide5% Ammonium Hydroxide1% Nitric Acid1% Sodium Hypochlorite*121 days in full Immersion – ** 700% LOWER than pH-1NPR-5300 Epoxy EXCEEDED All Corrosion Performance Requirements
11County Sanitation Districts of Los Angeles Manhole Test “NeoPoxy NPR-5300 Series in Acid Vat C97 was inspected on 12/8/03 after 5 months exposure to 10% H2SO4. So far, there is no color change or evidence of any problems. The test will be completed in about 7 more months.”County Sanitation Districts of Los Angeles County
12PureEpoxy Liners 100% Solids, No VOC’s No SolventsLow OdorsNo ShrinkageMoisture TolerantCures UnderwaterEnvironmentally Friendly
13The Solution That Works DIRECT-TO-AGGREGATEBONDING
14Direct-To-Aggregate Advantages Cement is the “weakest link” of manhole materials. Smooth with cement minimally in joints & larger holes.Direct-To-Aggregate bonding is the strongest, most reliable design. Like sandblasting, it increases surface area and increases pull-off strength.
15Insures that minor cleaning issues do not impact 50 year service life Bonding To AggregateAggregate Does Not CorrodePerfect Adhesion SurfaceDeeply Anchored3-D Encapsulated AggregateAtomic-Level Chemical AdhesionPerfect Bond & SealInsures that minor cleaning issues do not impact 50 year service life
17Water Load Bearing462’ Water HeadForceAssumption: One square inch aggregate spacing AND no adhesion to mortar.Fact: The minimum force to pull off one square inch of embedded aggregate is 200 psi or 462 feet of hydrostatic head.
19New Pipe Connections Insert Pipe Break through concrete1) Cut hole 2) Seal against any incoming water 3) Finish With Epoxy Seal
20Additional Pipe Connections FinishedSeal Connection With Epoxy1) Cut hole 2) Seal against any incoming water 3) Finish With Epoxy Seal
21Preparation & Lining SIMPLE and Reliable! Preparation & Lining Water psiConfirm Surface pH of 6 - 9Fill & Patch With Cement or EpoxyApply 250 Mils Epoxy LinerSIMPLE and Reliable!* Direct To Aggregate
22How Does Ambient Cure Epoxy Improve Long-Term Performance? Thermal coefficient of expansion and contraction causes heat cured materials to contract during cool down. Ambient cure epoxy stays physically “tuned” to the substrate for maximum adhesion and a 50-year life expectancy.No annulus for an H2S penetration path.
23Chimney Seal Epoxy 500% Elongation Traffic Loads OK Freeze-Thaw OK Joints & Seams OKPermanently stops infiltration at rings, seals & moving joints. One step process
24Significant Design Points 50-Year Designs are the most economical, reliable rehabilitation solutions.Third Party testing combined with an ASTM design insures that liners perform throughout their 50-year design life.Direct To Aggregate bonding is the strongest, best long-term solution for a conservative 50-year design life.
25Cost/Benefit Advantages Mobilization Costs remain the same as for most other methods. Only material costs change, and for only a small percentage increase you get solid protection50-Year Design provides reliable assurance of performanceLowest Lifetime Maintenance CostPreserves System Investment