NeoPoxy 50-Year Design Life Structures Using Traditional Materials David H. Johnson, NeoPoxy Corp. An engineering guide for economical long-life rehabilitation and protection.

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? Cement relining Bag liners Mechanically locked PVC Polyurea & Polyurethane PureEpoxy Lining Systems

Why Use A 50-Year PureEpoxy Structural Design? 34 Foot Structural Liner – One of 43 Manholes – Eliminate Failures Enhances Host Structure Delivers Long-Term Value 25-Year Proven Design 50-Year Materials Experience

Why Use PureEpoxy Liners? Monolithic Protection No annulus Impervious to H2S Unaffected by Caustic or Acid ASTM Design-Compliant

Why Use An ASTM Design? 25-Year Reliability No Corrosion Failures No Structural Failures Conservative, Predictable & Safe ASTM – An International Standard

ASTM F1216 Wall 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 ASTM F1216-98 “Partially Deteriorated” Design Formula Thickness increases with load Epoxy’s Recognized Bonding Characteristics Provides A Massive Safety Factor

ASTM F1216 Wall Thickness vs.. Hydrostatic Load Partially Deteriorated Design NPR-5300 Wall thickness design increases from 0.25” after the water table is reached

Typical 4’ ID Manhole Wall Thickness 0.25” (250 mils) Avg. Water Table Increasing Thickness With Greater Load 10’ of water= 0.44” 20’ = of water 0.55” 30’ = of water 0.63”

Recognized Corrosion Resistance Requirements ASTM F1216-95 City of Los Angeles* 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 *121 days in full Immersion – ** 700% LOWER than pH-1 NPR-5300 Epoxy EXCEEDED All Corrosion Performance Requirements

County 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

PureEpoxy Liners 100% Solids, No VOC’s No Solvents Low Odors No Shrinkage Moisture Tolerant Cures Underwater Environmentally Friendly

The Solution That Works DIRECT-TO-AGGREGATE BONDING

Direct-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.

Insures that minor cleaning issues do not impact 50 year service life Bonding 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 & Benefits Bonded Beam Design Flexural Modulus Driven Groundwater Bonded Beam Design Flexural Modulus Driven Adhesion Is Greater Than Strength of Substrate Cannot Peel Cannot Blister Cannot Buckle

Water Load Bearing 462’ Water Head Force 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.

Mechanical Benefits Impact Tolerant Aggregate Protects Substrate Scratches & Nicks Rarely Reach Cement Aggregate Acts As Corrosion Restrictor Any Damage Easily Field Repairable

New Pipe Connections Insert Pipe Break through concrete 1) Cut hole 2) Seal against any incoming water 3) Finish With Epoxy Seal

Additional Pipe Connections Finished Seal Connection With Epoxy 1) Cut hole 2) Seal against any incoming water 3) Finish With Epoxy Seal

Preparation & Lining SIMPLE and Reliable! Preparation & Lining Water Blast @ 3500-5000 psi Confirm Surface pH of 6 - 9 Fill & Patch With Cement or Epoxy Apply 250 Mils Epoxy Liner SIMPLE and Reliable! * Direct To Aggregate

How 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.

Chimney 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 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 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

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Other Great NeoPoxy Products Potable & Wastewater Pressure Lining Systems Heat & Chemical Resistant Epoxy to 300°F Environmental Epoxy for Sewer & Storm Drains

Thank you! Thank YOU! …for letting us discuss PureEpoxy rehabilitation and protection. www.NeoPoxy.com (925) 560-1500

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