NeoPoxy 50-YearNeoPoxy 50-YearDesign Life StructuresDesign Life Structures

Using Traditional MaterialsUsing Traditional Materials

An engineering guide

for economical

long-life rehabilitation

and protection.

David H. Johnson, NeoPoxy Corp.

What Are The Problems?What Are The Problems?

• Hydrogen Sulfide/Sulfuric Acid Attack

• Reduced I&I is lowering flow rates

• Acid generation is increasing

• Deterioration rate is rapidly increasing

• System investment is being lost

What Are The Solutions?What Are The Solutions?

• Cement relining

• Bag liners

• Mechanically locked PVC

• Polyurea & Polyurethane

• PureEpoxy Lining Systems

Why Use A 50-YearWhy Use A 50-YearPureEpoxy Structural Design?PureEpoxy Structural Design?

• Eliminate Failures• Enhances Host Structure• Delivers Long-Term Value• 25-Year Proven Design• 50-Year Materials Experience

34 Foot Structural Liner – One of 43 Manholes –

Why Use PureEpoxy Liners?Why Use PureEpoxy Liners?

• Monolithic Protection• No annulus• Impervious to H2S• Unaffected by Caustic or Acid• ASTM Design-Compliant

Why Use An ASTM Design?Why Use An ASTM Design?

• 25-Year Reliability• No Corrosion Failures• No Structural Failures• Conservative, Predictable & Safe• ASTM – An International Standard

ASTM F1216ASTM F1216Wall Thickness DesignWall Thickness Design

• P = groundwater load

• k = enhacement factor

• EL = long term flexural modulus

• v = Poissons ratio

• SDR = standard dimensional ratio

• C = ovality reduction factor

• N = safety factor

Epoxy’s Recognized Bonding Characteristics Provides A Massive Safety Factor

NCSDRvkEPLcr •−−= 32 )1(112ASTM F1216-98 “Partially

Deteriorated” Design Formula

Thickness increases with load

ASTM F1216 Wall Thickness vs.. ASTM F1216 Wall Thickness vs.. Hydrostatic LoadHydrostatic Load

Wall thickness design increases from 0.25” after the water table is reached

Chemtron Technology & Engineering

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

0.50

0.55

0.60

0.65

0.70

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Depth of Hydrostatic Load (ft)

Gas-Guard UHB

Thickness Vs. Load

48 inch Diameter Barrel

Partially Deteriorated Design

NPR-5300

Typical 4’ IDTypical 4’ IDManhole Wall ThicknessManhole Wall Thickness

Increasing Thickness With Greater Load

0.25” (250 mils)

Avg. Water Table

10’ of water= 0.44”

20’ = of water 0.55”

30’ = of water 0.63”

Recognized Corrosion Recognized Corrosion Resistance RequirementsResistance Requirements

• 10% Sulfuric Acid• 5% Nitric Acid• 10% Phosphoric Acid• Gasoline• Tap Water

• 31% Sulfuric Acid**• 5% Sodium Hydroxide• 5% Ammonium Hydroxide• 1% Nitric Acid• 1% Sodium Hypochlorite

ASTM F1216-95 City of Los Angeles*

*121 days in full Immersion – ** 700% LOWER than pH-1

NPR-5300 Epoxy EXCEEDED All Corrosion Performance Requirements

County Sanitation Districts of Los County Sanitation Districts of Los Angeles Manhole TestAngeles 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

PureEpoxy LinersPureEpoxy Liners100% Solids, No VOC’s100% Solids, No VOC’s

No Solvents

Low Odors

No Shrinkage

Moisture Tolerant

Cures Underwater

Environmentally Friendly

The Solution That WorksThe Solution That Works

DIRECT-TO-AGGREGATE

BONDING

Direct-To-Aggregate AdvantagesDirect-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.

Bonding To AggregateBonding To Aggregate

• Aggregate Does Not Corrode• Perfect Adhesion Surface• Deeply Anchored• 3-D Encapsulated Aggregate• Atomic-Level Chemical Adhesion• Perfect Bond & Seal

Insures that minor cleaning issues do not impact 50 year service life

Design & BenefitsDesign & Benefits

• Bonded Beam Design• Flexural Modulus Driven• Adhesion Is Greater Than Strength of Substrate

• Cannot Peel• Cannot Blister• Cannot Buckle

Groundwater

Water Load BearingWater Load Bearing

Assumption: 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.

462’ 462’ Water Water HeadHead

Force

Mechanical BenefitsMechanical Benefits

• Impact Tolerant

• Aggregate Protects Substrate

• Scratches & Nicks Rarely Reach Cement

• Aggregate Acts As Corrosion Restrictor

• Any Damage Easily Field Repairable

New Pipe ConnectionsNew Pipe Connections

1) Cut hole 2) Seal against any incoming water 3) Finish With Epoxy Seal

Insert Pipe

Break through concrete

Additional Pipe ConnectionsAdditional Pipe Connections

1) Cut hole 2) Seal against any incoming water 3) Finish With Epoxy Seal

Finished

Seal Connection With Epoxy

Preparation & LiningPreparation & Lining

• Preparation & Lining

• Water Blast @ 3500-5000 psi

• Confirm Surface pH of 6 - 9

• Fill & Patch With Cement or Epoxy

• Apply 250 Mils Epoxy Liner

* Direct To Aggregate

SIMPLE and Reliable!

How Does Ambient Cure Epoxy How Does Ambient Cure Epoxy Improve Long-Term Performance?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.

Chimney Seal EpoxyChimney Seal Epoxy

• 500% Elongation• Traffic Loads OK• Freeze-Thaw OK• Joints & Seams OK

Permanently stops infiltration at rings, seals & moving joints. One step process

Significant Design PointsSignificant 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.

Cost/Benefit AdvantagesCost/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 protection

50-Year Design provides reliable assurance of performance

Lowest Lifetime Maintenance Cost

Preserves System Investment

Certified Applicator NetworkCertified Applicator Network

Other Great NeoPoxy Other Great NeoPoxy ProductsProducts

• Potable & Wastewater Pressure Lining Systems• Heat & Chemical Resistant Epoxy to 300°F• Environmental Epoxy for Sewer & Storm Drains

www.NeoPoxy.com(925) 560-1500

Thank YOU!…for letting us discuss PureEpoxy rehabilitation and protection.

Thank you!Thank you!

www.NeoPoxy.com(925) 560-1500

Photo Collection of WorksPhoto Collection of Works