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NeoPoxy 50-Year Design Life Structures Using Traditional Materials An engineering design guide for economical long-life rehabilitation construction and protection. David H. Johnson, President, NeoPoxy Corp.
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Why Use A 50 Year PureEpoxy Structural Design? Eliminate Failures Enhance Host Structure Receive Long-Term Value 25-Year Proven Design 50-Year Materials Experience 34 Foot Structural Liner – One of 43 Units –
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Why Use PureEpoxy? Seamless, Monolithic Protection Impervious to H 2 S Unaffected by Caustic or Acid ASTM Designs Liner After 4 Year Exposure To Severe H 2 S
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Why Use An ASTM Design? ASTM Is A National Standard Third Party Testing Requirement 25 Years, CIPP Pipe Design Success 25 Years, No Corrosion Failures 25 Years, No Structural Failures Reliable, Conservative & Predictable
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ASTM Liner Design Inputs Flexural Modulus: Short-Term Bending Resistance Creep Reduction: Long-Term Modulus Reduction Structure Ovality: Percent Out-of-Round Enhancement Factor: Tightness of Fit to Host Poisson’s Ratio: Thinning While In Tensile Pull Hydrostatic Loads: Known Ground Water Forces
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ASTM F1216 Wall Thickness Design P = groundwater load k = enhacement factor E L = 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 ASTM F1216-98 “Partially Deteriorated” Design Formula Thickness increases with load
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Recognized Corrosion Resistance 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 F1216-95City of Los Angeles* *121 days in full Immersion – ** 700% LOWER than pH-1 NPR-5300 Epoxy EXCEEDED All Corrosion Performance Requirements
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Typical 4’ ID Manhole 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”
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ASTM F1216 Wall Thickness vs.. Hydrostatic Load Wall thickness design increases from 0.25” after the water table is reached Partially Deteriorated Design NPR-5300
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PureEpoxy Liners 100% Solids, No VOC’s No Solvents Low Odors No Shrinkage Moisture Tolerant Cures Underwater Environmentally Friendly
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The Solution That Works DIRECT-TO-AGGREGATE BONDING
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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.
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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
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Design & Benefits Bonded Beam Design Flexural Modulus Driven Adhesion Is Greater Than Strength of Substrate Cannot Peel Cannot Blister Cannot Buckle Groundwater
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Water 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’ Water Head Force
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Mechanical Benefits Impact Tolerant Aggregate Protects Substrate Scratches & Nicks Rarely Reach Cement Aggregate Acts As Corrosion Restrictor Any Damage Easily Field Repairable
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New Pipe Connections 1) Cut hole 2) Seal against any incoming water 3) Finish With Epoxy Seal Insert Pipe Break through concrete
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Additional Pipe Connections 1) Cut hole 2) Seal against any incoming water 3) Finish With Epoxy Seal Finished Seal Connection With Epoxy
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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!
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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 H 2 S penetration path.
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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
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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.
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Cost/Benefit Advantages Mobilization Costs remain the same as for other methods. Only material costs change, and for only a small percentage increase you get real “meat on the bone.” 50-Year Design provides a reliable assurance of performance. Lowest Lifetime Maintenance Costs
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Other NeoPoxy Products Potable Water Structural Lining Systems Heat & Chemical Resistant Epoxy to 300°F Environmental Epoxy for Sewer & Storm Toll Free 800-767-3746
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www.NeoPoxy.com (925) 560-1500 Thank YOU! Thank you for visiting our web site. Please come back again for updates
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