Gravity Sanitary Sewer Pipe Material Comparison. Jeff Boschert, P.E. National Clay Pipe Institute

Transcription

1 Gravity Sanitary Sewer Pipe Material Comparison Jeff Boschert, P.E. National Clay Pipe Institute National Clay Pipe Institute, 2013

2 Presentation Outline A. Introduction to Modern Day Vitrified Clay Pipe B. Gravity Sanitary Pipe Material Characteristics Compared Side by Side 1. Structural Properties 2. Pipe Service Life 3. Corrosion Resistance 4. Abrasion Resistance 5. Field Acceptance Testing 6. Environmental Impact 7. Jointing System

3 Vitrified Clay Body Evolution Laminations within cross section Average Compressive Strength = 18,000 psi (125 MPa)

4 Vitrified Clay Pipe is the Predominant Jacking Pipe in the United States for Guided Boring Video is not available in PDF format. Please click here to view on the NCPI YouTube Channel.

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8 Static Pipe Bursting

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12 Sewer Authorities Who Are Specifying Vitrified Clay Pipe New York Los Angeles Chicago Phoenix Philadelphia Cleveland Minneapolis San Francisco Sacramento Area Sewer Dist., CA Sioux City Seattle Omaha New Castle County, DE Buckeye, AZ

13 George Cowan, P.E., Assistant Commissioner- Infrastructures Division, New York City Dept. of Design and Construction For new pipe, our preference is clay pipe.we believe our biggest expense is digging the trench, so we feel it s worth the extra cost to get what we believe is the best pipe. Source: Roundtable Discussion; pp Trenchless Technology Magazine; JULY 2006

14 Section 1 Structural Properties

15 Rigid Pipe Open Trench Design Determining Predicted Load (W c ) Determining Field Supporting Strength FSS = Pipe Strength x Bedding Factor Calculating Safety Factor Safety Factor = Field Supporting Strength Predicted Load

16 Rigid Pipe Load Equation Wc B d W c = Total Predicted Load C d = Load Calculation Coefficient w = Soil Weight B d = Trench Width at Crown W c = C d wb d 2

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20 Flexible Pipe Deflection Equation % Deflection = ΔX = D L KW c r 3 I E r 3 Where: ΔX = Horizontal deflection of pipe (inches) D L = Deflection Lag Factor (1.0 or 1.5 Typical) K = Bedding Constant (0.1 Typical) W c = Prism Load = Weight of soil over pipe (lbs./inch) r = Mean radius of the pipe (inches) E = Modulus of Elasticity of pipe material (psi) I = Moment of Inertia of the pipe wall per unit length (inch 3 ) E = Modulus of Soil Reaction (psi) Source: Handbook of PVC Pipe, Equation 7.8, Chapter 7, page 228 Uni-Bell PVC Pipe Association, 2001

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22 Thermoplastic Materials Degrade with Age The main feature of plastics and polymer composites is that their physical, mechanical, thermal and chemical properties are strongly time and temperature dependent. Source: Dr. Mehdi Farshad: Plastic Pipe Systems: Failure Investigation and Diagnosis 2006

23 When considering the design and development of a plastic component, it is imperative that designers and engineers fully understand the fundamental nature of plastics. They should know that plastics are non-linear, visco-elastic materials with temperature/ time-dependant properties. Plastics physically and chemically age, and are susceptible to chemical attack, environmental stress cracking (ESC), and weathering. Source: Long-Term Testing Critical for Material Selection; Chris O Conner; pp Modern Plastics Worldwide; October 2007

24 Even untouched, these cultural symbols will inevitably grow brittle, warp and crack.... The problem of polymer materials in museums is getting to be bigger and bigger" Source: WARP SPEED, The Dallas Morning News, August 28, 2000; Sue Goetinck Ambrose; Science writer; page 2F

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26 Type 1 Soils: Rock, cemented soils, 95% standard proctor, sands and gravels with in place densities of 70% or higher Type 2 Soils: sands and gravels with in place densities of 40 to 70%, silts or 85% standard proctor or higher Type 3 Soils: Peat or other organic soils, elastic silts, low density silty or clayey soils with a density below 85%, low density cohesionless soils with an in place density below 40% Source: Pipeline Installation, Amster Howard, 1996 Chapter 5

27 Section 2 Pipe Service Life

28 Vitrified Clay Pipe is the only sewer pipe material recognized by the U.S. Army Corps of Engineers with a 100 year service life. Clay Pipe is perhaps the most inert of the common pipe materials in terms of corrosion, and it is very resistant to abrasion. A 100- year service life may be assumed for most clay pipe installations. Source: Life Cycle Cost for Drainage Structures, US Army Corps of Engineers, 1988

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30 8-Inch VCP Installed Prior to Years Old! Video is not available in PDF format. Please click here to view on the NCPI YouTube Channel.

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35 10-Inch PVC Installed in 1991 Video is not available in PDF format. Please click here to view on the NCPI YouTube Channel. Replaced with 10-Inch VCP in 2009

36 Section 3 Corrosion Resistance

37 Chemical Resistance Sewerage generates Hydrogen Sulfide which is converted to Sulfuric Acid in the sewers. - Both Vitrified Clay and Thermoplastic pipe materials are resistant to Sulfuric Acid. Solvent based chemicals - Thermoplastic materials are susceptible to corrosion.

38 Chemical Resistance Comparison Material Normal domestic sewage Trade effluent Soil At normal Containing fats and At sustained environment temperature Organic oils high temp. containing Acids Alkalis solvents Vegetable Mineral Acids Alkalis Sulphates Acids Vitrified Clay pipes and fittings S S S S S S O O S S Polyethylene O O S X O O X O S S PVC O S S X O O X X S S Glass Reinforced Polyester (GRP) O P P X O O X X O O S = Specially suitable P = May require special protection O = Normally suitable X = Expert advice desirable, e.g. from specialist or manufacturer Source: Pipelines: An Overview, Loai Na amani

39 Chemicals Affecting PVC, PE & Fiberglass Pipe > PPI identifies 116 Chemicals that PVC is not resistant to. And another 155 Chemicals are listed as no data available. > PPI identifies 20 Chemicals that PE is not resistant to. And another 198 Chemicals are listed as no data available. > Hobas identifies 143 Chemicals that fiberglass is not resistant to. And another 138 Chemicals are listed as no data currently available. Sources: Chemical Resistance of Thermoplastic Piping Materials, Plastics Pipe Institute, September, 2007 The Complete HOBAS Guide, Hobas Pipe USA, Appendix F, Corrosion Resistance Guide, pp

40 Vitrified Clay Pipe is inert The only chemical that may damage VCP is Hydrofluoric Acid (HF).

41 Section 4 Abrasion Resistance

42 Abrasion Resistance Testing of Sewer Pipe Materials The tests were obtained by rotating pipe sections at a rate of 2.5 fps for 500 hours. The abrasive charge consisted of 7 pounds of #67 (ASTM D 448) limestone aggregate and 6.6 pounds of water which was changed every 48 hours. Pipe (All 8 Diameter) Wall Thickness Abraded Percent Abraded Vitrified Clay Solid Wall PVC Solid Wall PVC with bulk fillers Profile Wall PVC (a) PVC Truss (a) ABS Truss (a) lining Note (a): Complete Abrasion through the interior Pipe Stiffness Test (ASTM D Diameter) Pipe Minimum Required After Abrasion % Under Minimum Solid Wall PVC (ASTM D 3034) 46 psi 32.1 psi 30.2 % Solid Wall PVC (ASTM F 789) 46 psi 19.2 psi 58.3 % Profile Wall PVC 46 psi 28.6 psi 37.8 % PVC Truss (ASTM D 2680) 200 psi psi 23.7 % ABS Truss (ASTM D 2680) 200 psi psi 28.3 %

43 Definition of Fillers in PVC Resin Fillers are particulate materials that when added to the resin extend its volume and lower costs. Source: Modern Plastics World Encyclopedia 2001, Page C-14

44 Greenbook PVC Filler Specification Additives and fillers, including but not limited to stabilizers, antioxidants, lubricants, colorants, etc., shall not exceed 10 parts by weight per 100 of PVC resin in the compound. Source: Greenbook Standard Specifications for Public Works Construction 2012 Edition, Section Cell Classification, page 169

45 Section 5 Field Acceptance Testing

46 Rigid Pipe Acceptance Testing ASTM C Low Pressure Air Test

47 Flexible Pipe Deflection Testing Deflection Mandrel Laser Profiling

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49 Laser Profiling of a Flexible Conduit Video is not available in PDF format. Please click here to view on the NCPI YouTube Channel. Video courtesy of Cues, Inc

50 Pipe x axis = 7.936

51 Pipe y axis = 7.874

52 Measurements x = 7.936; y = Average is: ASTM D 3034 SDR-35 is (+/ ) ASTM D 3034 Standard Specification for Type PSM Poly(Vinyl Chloride) (PVC) Sewer Pipe and Fittings (Table X1.1) Size Average Inside Diameter Base Inside Diameter 7.5% Deflection Mandrel

53 Actual Manufactured Average I.D inches 10.2% of Actual Pipe Diameter Base I.D inches ASTM D % Mandrel 7.09 inches (calculated from Base I.D.)

54 Section 6 Environmental Impact

55 Green Certification Programs There are over 400 sustainable products standards and/or certifications on the market.

56 Multi-Attribute Certified Sustainable Products Multi-attribute sustainable products have the highest market value because they advance the triple bottom line: Environment, Economy and Social Equity. SMaRT incorporates 41 single attribute standards.

57 SMaRT Certification System Sustainable Materials Rating Technology (SMaRT) Similar to the LEED system for building components, it is a transparent, third party certification program that considers the triple bottom line of environmental, social and economic costs. The SMaRT standard analyzes the impacts of a product s entire lifecycle, from raw materials extraction to manufacturing and transportation through end-use, disposal or recycling.

58 SMaRT Products Contribute to LEED Points Directly & Indirectly Direct LEED Contribution SMaRT Certified Sustainable are approved for LEED Innovation in Design (ID) Credits up to 2 pts total, Accessories Pilot Credit 43- Certified Products / EPDs, & LCA Pilot Credit. Lighting Phillips T8 Lamps Paints & Coatings AkzoNobel Powder Coating - Platinum Electrical Distribution Eaton Busway Eaton Lighting Control Panel Eaton UPS ELECTRICAL Philips T8 Lamps Gold Eaton Uninterrupted Power System Gold Eaton Busway - Gold Infrastructure Vitrified Clay Pipe Gold Ductile Iron Pipe Gold HARDWARE / FLOORING Forbo Linoleum - Platinum Forbo Furniture Linoleum - Platinum Forbo Bulletin Board Linoleum - Platinum Milliken Modular Carpet Tile Platinum Copeland Furniture Silver Durham Furniture Inc. Silver Harden Furniture Silver West Bros Furniture Silver Brown Street Furniture / Vermont Tubbs Silver Indirect LEED Contribution SMaRT Certified products can help contribute to your recycled content, energy reduction/management, lighting and more to earn points for your LEED Structure Forbo Bulletin Board Marmoleum - Gold Office Furniture Knoll Chairs Knoll File Systems Knoll Storage Systems Knoll Wood Surface Furniture Knoll ReGeneration EPD Forbo Furniture Marmoleum Doors Securall Doors - Gold Flooring Forbo Marmoleum - Platinum Milliken Carpet - Platinum Milliken Tile - Platinum FURNITURE Knoll Life Chair - Gold Knoll Chadwick Chair - Gold Knoll Generation Chair Platinum Knoll ReGeneration EPD Knoll Moment Chair - Gold Knoll Calibre Files Furniture Systems Gold Knoll Calibre Mobile Pedestal Furniture Systems Gold Knoll Calibre Fixed Pedestal Furniture Systems Gold Knoll Calibre Overhead Storage Furniture Systems Gold Knoll Calibre Storage Closet Furniture Systems Gold Knoll Template Wood Surfaces Furniture Systems Gold Knoll Template Steel Surfaces Furniture Systems Gold Knoll Template Glass Surfaces Furniture Systems Gold

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60 PVC is one of the most environmentally hazardous consumer materials ever produced. PVC is the antithesis of a green building material. Efforts to speed adoption of safer, viable substitute building materials can have significant, tangible benefits for human health and the environment. Source: Environmental Impacts of Polyvinyl Chloride Building Materials Joe Thornton, Ph.D.

61 THE ENVISION RATING SYSTEM

62 Envision was developed in joint collaboration between the Zofnass Program for Sustainable Infrastructure at the Harvard University Graduate School of Design and the Institute for Sustainable Infrastructure. The Institute for Sustainable Infrastructure is a not-for-profit education and research organization founded by the American Public Works Association, the American Council of Engineering Companies and the American Society of Civil Engineers.

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64 Section 7 Jointing Systems

65 Yesterday s Jointing Systems Arkansas Oct 1922

66 Yesterday s Jointing Systems Arkansas Oct 1922

67 Clay Joints Last Century & This Century

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69 The Solution to Pollution is Dilution Source: American Sewerage Practice by Metcalf and Eddy, 1935

70 Polyurethane Compression Joint

71 O-Ring Compression Joint

72 O-Ring Compression Joint Assembly Video is not available in PDF format. Please click here to view on the NCPI YouTube Channel.

73 Plastics Two Major Categories: 1. Thermoset or thermosetting plastics. Once cooled and hardened, these plastics retain their shapes and cannot return to their original form. They are hard and durable. Thermosets can be used for auto parts, aircraft parts and tires. Examples include polyurethanes, polyesters, and epoxy resins. 2. Thermoplastics. Less rigid than thermosets, thermoplastics can soften upon heating and return to their original form. They are easily molded and extruded into films, fibers and packaging. Examples include polyethylene (PE), polypropylene (PP) and polyvinyl chloride (PVC). THESE MATERIALS CHANGE WITH AGE.

74 ASTM C 425 Joint Performance Verification The Joint shall not leak. Assembled pipe sections are filled with water and pressurized Shear Loaded 150 lbf/inch of nominal diameter Deflected to simulate extreme settlement

75 University of Houston Compression Joint Testing Tested 30 inch VCP, RCP,PVC, and FRP pipe. Using an external pressurized bladder assembled joints were tested in straight alignment, angular deflection, and shear load. Straight and Angular Deflection Tests: All pipe passed the 7 psi external test pressure without leakage. Shear Load Test: Only VCP exceeded the test protocol of 4500 lbs without leakage.

76 Joint Shear Load Test Shear Load (lbs) PVC FRP RCP VCP 0 30 inch Pipe Material Shear Load Test: The PVC and FRP pipe were tested at lower shear load values at the request of the plastic pipe industry.

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79 NCPI is on the Road To join us for a small group demonstration in your area, please contact our office at: (262) or info@ncpi.org

80 Questions? Jeff Boschert, P.E. National Clay Pipe Institute (314) Cell National Clay Pipe Institute, 2013