Fusible PVC® PipePresentation

Contemporary Topics in Water/Wastewater Construction Seminar

Goldsboro, NC

December 4, 2018

Company Confidential

Today’s Discussion…• Aegion Infrastructure Platform Products

• Background and History of Butt-Fused PVC Pipe

• Understanding Fusion of PVC Pipe

– Process

– Data Logging Joints

– Certification of Technicians

• Multi-layered Product QA

– In Plant

– Independent Lab

• Benefits of Fusible PVC® Pipe; Comparison to HDPE

– Material characteristics

– ID/OD relationship

– Flexibility & toughness

– Practical field differences

• Primary Application – Horizontal Directional Drilling, Design & Case Study

• Other Applications – Sliplining, Jack & Bore, Pipe Bursting & Open Cut

Infrastructure Platform Products• There are four business units of the Infrastructure

Platform for new construction or rehabilitation of deteriorating water and wastewater pipelines.

- Cured-in-place pipe rehabilitation for gravity sewer lines, of which several billion

dollars’ worth installed.

- Insitumain is a CIPP liner designed specifically to rehabilitate pressure mains from 6”

to 36” diameter, for pressures upto 200 psi.

- Insitumain can be a fully structural element, designed to replace the existing main

should it corrode and fail entirely.

- For more information, review and download the information at

http://www.aegion.com/InfrastructureSolutions/PipeLiningsWater/InsituMain

- Fibrwrap developed the process of carbon reinforce polymer lining of large pressure

mains over 20 years ago.

- Repaired many discreet sections of pipe since that time.

- Process requires man entry and can be effective for diameters larger than 36” and

pressures over 400 psi.

- Fibrwrap system is meant for spot repairs, wherein a few lengths of pipe within a longer

section may need reinforcement.

- For more information, review and download the information at

http://www.aegion.com/InfrastructureSolutions/PipeLiningsWater/FRP

- Developed Tite Liner® to offer a corrosion

control solution in the oil and gas patch, and for

industrial uses.

- Process has great promise for municipal

wastewater force mains with beginning or

moderate stages of internal H2S corrosion.

- Corrosion in these force mains can be stopped

dead with this thin HDPE liner available from,

and installed by, UPS, as long as the underlying

main has adequate structural capacity to

perform the remainder of its design life.

- Diameters available up to 54”.

- For more information:

http://www.aegion.com/CorrosionProtection/Pipe

Linings/Tite-Liner

Bringing Innovation to Underground Infrastructure• Fastest growing underground infrastructure product-line in

North America

– Leak free, restrained joint pipe systems

– Trenchless installation modes that reduce contractor costs

– Rehabilitation capabilities for difficult high pressure water pipe

applications

– “Trenchless Project of the Year 2010 & 2013” “Honorable Mention 2007 & 2014” – Trenchless Technology magazine

• Over 11,000 successful projects installed to date with over 12,000,000 feet

in service worldwide

– In 50 states, Canada, Latin America, New Zealand, Australia

– Over 5,000 HDD’s (horizontal directional drills) completed

– Over 8,500 separate pull-in instances (HDD, Slipline, Pipe Burst, Open-Cut)

• Pipe meets relevant industry pipe standards

– AWWA C900, C905, C605, NSF-61, NSF-14, PPI-TR2, ASTM Cell Classification

12454

– Utilizes standard PVC and ductile iron fittings

– Available in all water industry configurations

Company Confidential

Fusible PVCTM Products – 40’ or 45’ Lengths, plain end x plain end; extruded by NAPCO and Northern to UGSI formula and quality standards

Pipe TypeSizes

(Nominal OD)

DIPS or IPS or

Schedule

Dimension Ratios (DR)

Uses Color

Fusible C-900® 4” – 12” DIPSDR 14, 18,

25

Potable Water

AWWA C900Blue

Fusible C-905® 14” – 36” DIPSDR 14, 18,

21, 25, 32.5, 41

Potable Water

AWWA C905Blue

FPVC® 4” – 36”DIPS, IPS,

or Schedule

DR 14,17,18, 21, 25, 26, 32.5, 41

and Sch.80

Non-Potable Water or Potable

Water Applications not

in C900/C905 Dimensions

Blue, Purple, Green, White,

Grey

* Not all diameters are extruded to all listed DR’s.

The Underground Solutions® PVC Fusion Process: Utilizes Industry Standard Fusion Equipment

Internal Bead not a flow restriction– friction losses are negligible (‘C’-factor of 150) and are significantly less than mechanically joined pipe.

Company Confidential

Fusible C-900®, Fusible C-905® And FPVC ® : Fusion Process Is Tightly Controlled• Qualified fusion technicians are trained and

retrained every year by Underground Solutions

– Initial 3 day course

• Fusion equipment must meet minimum company standards to be approved for PVC fusion

• Data loggers record critical fusion datafor each joint– Provide real time feedback on joint integrity– Provide record of entire project for proof of system

integrity

• Fusion conditions logged by technician and “as-built” fusion joint record is developed for owner as necessary

30111

Myrtle Beach 20" Force Main Diversion

Myrtle Beach, SC

Eric Kerner

Eric Kerner

Pipe DR

DR 25

Piston

Area (in2)

15.32

A. Pressures (psi) B. Ambient Conditions / Start Time

Heat

Fusion

Drag AM

AM

C. Heating Plate Temperature & Extrusion Marking

Left Face Temperature - °F Right Face Temperature - °F

Record extruder pipe marking (near fusion joint) and pipe length above.

Fusion Technician

Pipe Dia. (in)

Jobsite Location

Pipe Description

PIPE DETAILS

Color Extruder

Pull No.

21462810604-1172

NAPCO FPVC™20004

MDL3-0241

Green

C09247

Data Logger Serial

No.Heat Plate Serial ID

EQUIPMENT IDENTIFICATION

57Temp. (°F)

20

sunnyWeather

IR Pyrometer

Serial No.

50

564

T-900

Project No.

Joint Number

20004

Nov. 29, 2007

Fusion Machine Identification

131

Joint No.

Fusion Date

Project Name

Project Engineer

399

15 Sept 07 @ 11:23 12 Nov 07 @ 17:47

412

399

402

410

402 395403

10:52

End Time 11:29

Start Time

235188

Piv

ot

12:00

3:00

6:00

9:00

12:00

3:00

6:00

9:00

Growth in Carolinas Region

• NC > 485,000• SC > 311,000

NCDOT Standards -2012

Fusible PVCTM is the Most Tested PVC Pipe in the Industry with Four Levels of Quality Control to Help Ensure Flawless Installations: Over 10,000 Specimens Tested by 3rd Party Labs

Test AWWA

Requirements

UGSI Requirements UGSI Lot

Acceptance

Testing

Fusion Joint QC

Data

Fusion Tensile ASTM D638

Pipe Tensile ASTM D638

Pipe Dimensions Per AWWA

C900/C905

Per AWWA

C900/C905

Pipe Burst Per AWWA C900 Per AWWA C900

Flattening Per AWWA

C900/C905

Per AWWA

C900/C905

Per AWWA

C900/C905

Acetone Immersion ASTM D2152 ASTM D2152 ASTM D2152

Hydrostatic

Pressure Test

Per AWWA

C900/C905

Per AWWA

C900/C905

Impact Test ASTM D2241;

ASTM D2444

Heat Reversion ASTM F1057 ASTM F1057

Ash/Inert Content (LOI) ASTM D2584

Joint Fusion

Parameters

Temperature

Pressure, Location, Other

Licensed Operator Unique Operator ID

Thousands of Hours and Thousands of Individual Sample Tests by Independent Sources further Verify Mechanical Properties of UGSI Fusible PVCTM

• Tensile Strength – >1000 fused samples verify fused joint strength ~ 7000 psi ultimate tensile strength or typically 95-105% of the un-fused pipe strength (within the variability found in commercial PVC pipe)

• 1000 Hour Sustained Pressure Test - per ASTM D1598 at 500psi (DR18) for 10x the ASTM threshold of 1000 hours – UGSI test duration was 10,000 hours – fused and un-fused pipe

• 1,000,000 Cycle Pressure Test – (94-188psi for DR18) demonstrating cyclic surge on a fused joint system per ASTM F1674 – simulating a severe duty cycle (3.5 million completed)

• 5000 Hour Scratch/Pressure Test – Gouge depths of 5-10% on samples under 500psi (DR18) pressure were successfully tested (pipe and fused joint)

Fusible PVC® Pipe Physical / Mechanical Material Properties Are Very Different From HDPE Pipe

Property Specification PVC PE80 PE4710 Diff.

Tensile Strength (psi) ASTM D638 7,000 3,000 3,000 >2X

Safe Pulling Stress (psi) (w/SF = 2.5) 2,800 1,200 1,200 >2X

Specific Gravity ASTM D1505 1.40 0.94 0.95

Hydrostatic DesignBasis At 73º F (psi)

ASTM D2837 4,000 1,600 2.5X

Modulus of Elasticity (psi)

ASTM D638 400,000 110,000/28,200* 3.6X

Hardness(Rockwell R)

ASTM D785 117 52 2.25X

Coefficient of Linear Expansion In./In. deg F

ASTM D6960.3 x 10-4

.36”/ 100’/ 10°F

1.2 x 10-4

1.44”/ 100’/ 10°F0.25X

* PPI – PE Handbook – Long term Modulus of Elasticity = 28,200 psi.

Bending differences • HDPE is More Flexible Than PVC…

But, PVC is Stronger and Requires Less Wall Thickness for a Given Design…

OD= 13.20"ID= 11.65"

OD= 15.30"

PE

PVC

ID= 11.70"

12” DR18 PVC (DIPS)14” DR9 HDPE (DIPS)

Fixed ID and Pressure Rating Yields this Result for 24” ID, 200 psi

24” ID 24” PVC DR 21SF = 2.0

30” PE DR 9SF = 2.0

PVC % Advantage

OD (inches) 25.80 30.00 16%

Volume per Foot (ft3) 3.63 4.91 35%

Wall Thickness (inches) 1.23 3.33 171%

ID (inches) 23.19 22.93 1%

Pressure Rating (PSI) 200 200 0%

Weight (lbs./ft.) 61.49 121.62 98%

OD= 25.80"ID= 23.19"

OD= 30.00"

PE

PVC

ID= 22.93"

Borehole Comparison

HDD – Connection Points (PPI Recommends for HDPE…)

A typical pullout prevention technique is to restrain the transition connection and

several non-PE bell and spigot joints down line from the transition connection as

shown in Figure 26. From Plastics Pipe Institute Literature (Technical Note 36)

Connection Suggestion For Fusible PVC®

Fusible PVC™Mechanical Joint

Ductile Iron Solid Sleeve

EBAA Megalug® or Equal EBAA Megalug® or Equal

Joint Deflections,

only

Fusible PVC™

Fusible PVC™

Fusible PVC™ Mechanical Joint

Ductile Iron Bend

EBAA Megalug® or Equal

EBAA Megalug® or Equaldd

Open Cut DIP or PVC

Open Cut DIP or PVC

High Creep HDPE Typically Fused for Connections and Taps & Repairs

Scraper to prep surface for coupling Hammering on electrofusion coupling

Saddle fusion for tap or puncture repairMJ Adapter w/stiffener

Low Creep Fusible PVC® pipe uses industry standard couplings, MJ fittings and tapping procedures

Mechanical Joint Fittings:

Same Piping Size

Connecting to Fittings & Pipe Tapping Machines/Procedures

Pictures from various manufacturers of fittings: JCM, Smith Blair, EBAA Iron, Mueller.

HorizontalDirectional

Drilling

• 55%of UGSI Fusible PVC® installed by directional drilling techniques–Pulls of over 7,000 ft accomplished (AWWA C905 – 16”)–Pulls of over 7,000 ft accomplished (AWWA C905 – 30”)–Over 3,000 separate pull-ins–Pipe diameters of 4” - 36” installed

• 25% of UGSI Fusible PVC® installed in slip lining applications–Pull of over 7,000 ft accomplished with 14” pipe–Pull of over 3,500 ft accomplished with 12” pipe–Pull of over 1,800 ft accomplished with 24” pipe–Pipe diameters of 4”- 30” installed

• 15% of UGSI Fusible PVC® installed in direct-buryapplications

•5% of UGSI Fusible PVC® installed in pipe bursting applications

–- Pulls of over 2,000 ft accomplished with 8” and 10” pipe

PipeBursting

Open-Trench/Direct Bury

Sliplining

Underground Solutions Fusible PVC® is installed through two generic installation methods: Trenchless and Open-Cut

Fusible C-900 ®, Fusible C-905 ® and FPVC® Pipe Lower Costs

• Guided pilot hole is drilled along a bore path

• Drilling fluids are injected into the hole to stabilize and lubricate – fluids suspend and transport cuttings to the surface

• Back reamer is used to enlarge the pilot hole – Multiple passes are required to

accommodate pipe OD

– Drilled bore hole is typically enlarged to 1.5 x OD of new pipe

HorizontalDirectional

Drilling

Considerations

• Insertion trench is configured to meet bend radius of the pipe

• 120’ small pipe culvert crossings, or…• 7,000’ x 16” DR18 pulled in a single

continuous drill operation• No relaxation period required –

immediate connections possible• Higher density of Fusible PVC®

reduces buoyant forces to reduce pull-in forces

• Longer pull-ins possible – recommend water ballasting and rollers to reduce drag

HorizontalDirectional

Drilling

30” HDD Bore in Wilmington, NC 2012

Company Confidential

HDD –Entry/Exit Angles, Borepath & Radius

Slope or Tangent Portion

(8° to 15° - 20% is 11°)

Radius

Level Run (depends on obstacle crossed)

Depth

Company Confidential

HDD – Setbacks, Depth, Connection Points

Setback

Connection Point

Company Confidential

HDD – Radius Based on Rig Size

ASTM F1962 Guide for Maxi-Directional Drilling suggests 1200 times the

drill rod radius to determine minimum radius of drill stem:

• For 40,000# class rigs with 2.5” rods, that is 250’ radius

• For 100,000# class rigs with 4” rods, that is 400’ radius

• For 300,000# plus class rigs with 6” rods, that is 600’ radius

Rig size for your project depends on:

• Product pipe diameter

• Length and depth of drill shot

• Soils type or presence or rock

• Site conditions

• Local contractor capability

Company Confidential

HDD – Radius Check on Product Pipe

Fusible PVC™ pipe bend radii ranges (DIPS OD):

• 4” – 100’

• 6” – 144’

• 8” – 189’

• 12” – 275’

• 16” – 363’

• 20” – 450’

• 24” – 538’

• 30” – 667’

• 36” – 798’

Horizontal Directional Drilling with Fusible PVC® Pipe -

Columbia, SC- Mill Creek Forcemain

• HorizontalDirectional

Drilling

Client:

City of Columbia

1,665’ – 30” DR21

The final reaming pass used 42” rock bore tooling directly

in front of the 32” outside diameter product pipe.

Horizontal Directional Drilling with Fusible PVC® Pipe -Okatie, SC

Client:

Beaufort Jasper

1,300’ – 36” DR21

One Intermediate

Fusion

HorizontalDirectional

Drilling

North Topsail Waterline RehabNorth Topsail, NC

Onslow Water and Sewer Authority(Completed January 2018)

North Topsail Waterline Rehab

37

-35 yr old 10” DIP on Bridge

-Prolonged exposure to coastal

environment

-Corrosion, water leaks, and joint

deterioration

-Main water feed to Island

North Topsail Waterline Rehab• WK Dickson design

• 2 options for construction: short HDD and open cut or long HDD

• Approximately 2,025 ft. of HDD across ICWW

• Upsized line to 12”

• Tidal environment

• Approximately 20+ ft. below ICWW bottom

• Entry and Exit angles adjusted for topo

North Topsail Waterline Rehab

• 2,025’ – 12” in Single Pull

• Drill pipe entry angle about 12º, exit angle 10º

• Wire line tracing used to steer

• 9” Pilot drill took 6 days

• Swabbing pass to clean hole and set slurry cake took 5 days

• Ready to connect and pull pipe mid-December 2017

North Topsail Waterline Rehab

North Topsail Waterline Rehab

•Drilling Operations – Sandy’s Hauling

•330 k-lbs machine

•ParaTrack survey and guidance system utilized

North Topsail Waterline Rehab

Fusion required 45

joints over 6 days

Rollers supported pipe at 40’ intervals

Pipe String to

Driveway

North Topsail Waterline Rehab

•Took 60 days from NTP to test (150 psi/2 hrs) and reconnect

•Minimal impact to ICWW and wetlands

•70+ HDDs over 2,000 ft.

Compromised Host Pipe Has a Continuous Length of Fusible PVCTM Pulled Into Place

• Provides maximum flow with an independent fully structural solution

• Results in a smaller I.D. than the host pipe

• Improvement in internal friction often minimizes flow loss – “C” factor

• Grouting of the annular space between the existing and new pipe is usually required

Sliplining

Sliplining Project Considerations

• Video inspection of host pipe – condition, deflections, vertical profiles and stranded appurtenances

• Layout area for fused pipe – as well as entrance pit constraints – possibility for “fuse & pull” or in pit fusion

• Recommended difference between ID of host pipe and OD of Fusible PVCTM is about 2”

• Ability to dig out connections before sliplining

• Effect of abrasion on pipe surface – plastic 10% gouge depth before de-rating

• Traffic management – night activity or “fuse & pull” in tight areas

Sliplining

Client: DC Water

Consultant – CDM Smith

Sliplining with Fusible C-900® Pipe – M Street Water Main

• 1,800LF of 30” DR 25 Fusible C-905® pipe in 36” PCCP Host

• Pipe pulled in with Grundoburst 800G

Sliplining

DC Water-M Street WM

Fusible PVC C-905 vs HDPESliplining

DC Water-M Street WMWell designed Pit for Fusion

Sliplining

DC Water-M Street WMRoom to Maneuver & Perform Fusion Tasks

Sliplining

DC Water-M Street WM Static Machine Provides Pulling Force with Steel Rods

Sliplining

DC Water-M Street WM Pipe installed awaiting annular space grouting

Sliplining

Fusible PVC™ pipe is well suited to Jack & Bore installation

• Bore pits are dug on each side of the crossing

• Casing pipe is jacked into place while spoils are removed through the casing

• Carrier pipe is installed inside of new casing

http://www.energy.ca.gov

Jack & Bore

24" DR 18 FPVC®

inside 36" Steel Casing

OD= 25.80"

Casing ID= 35.00"

24" RJ Ductile Iron

inside 42" Steel Casing

w/ Casing Spacers

Pipe OD= 25.80"

Casing ID= 40.50"

Bell OD= 30.25"

45°30°

2" Conduit

45°30°

2" Conduit

Runner Height = 3.75"Runner Height = 1.50"

Jack & Bore with Fusible PVC® Pipe – Napa, CA

• 300 LF of 24” DR 18

• Jack & Bore crossing of Highway 221

• This section of pipeline provided approximately $50,000 in savings compared with other design options

Client: Napa Sanitation DistrictJack & Bore

Jack & Bore with Fusible PVC® Pipe – Eastvale, PA

• 24” DR 25 in a 42” steel casing

• Jack & Bore crossing under Norfolk Southern Railway

• By bundling Fusible PVC™ with the small diameter carrier pipes, the contractor was able to utilize a smaller diameter steel casing than with other pipe materials

Client: Beaver Falls Municipal AuthorityJack & Bore

Fusible C-900®, Fusible C-905®, And FPVC ® Pipe Attached to the Bursting Head and Pulled into the Existing Pipe

• Static Hydraulic Method is used

• Burst head is pulled through existing line - fracturing or cutting the pipe

• Fractured or split pipe is pushed into the surrounding soil

• New pipe is pulled in immediately behind the burst head

PipeBursting

Client: Greensboro Water Resources

City Wide Water Pipe Bursting ProgramPipe

Bursting

•Greensboro, NC

•58,000’ water main (to date)

•2, 4 & 6” Cast Iron to 6 & 8” Fusible

PVC™

•Through cast iron hubs and tees

•GrundoBurst 800G (over 160 tons of

pull)

•KRG Utility Performed Work

Pipe Bursting with Fusible PVC® pipe- Wilmington, NC

• 5039’ of 20” DR18 FPVC® Pipe- Longest Pull 900LF

• Replaced Corroded 20” Ductile Iron Pipe

• Performed in 5 months late 2014, early 2015

Client: Cape Fear Public Utilities Authority

Consultant: Kimley-HornPipe Bursting

Length of Fused Pipe with Pullhead and Expander Attached – up to 900 LF

Pipe String In Place for Pullback

Tooling Consists of Three Cutters, Each Subsequent One Larger than Last One

Removing Final Vestiges of Ductile Iron Pipe

Aegion Pressure Pipe Capabilities

62

4" 6" 8" 10" 12" 14" 16" 18" 20" 24" 30" 36" 42" 48" 54" 60" 66" 72"

InsituMain 258 195 160 255 220 195 175 161 256 227 190 165 145 130 115 108 100

Fusible PVC 305 305 305 305 305 305 305 305 305 235 200 200

Tite Liner 252 202 202 202 161 161 161 126 126 126 112 101 101 81 64

HDPE Slip Lining 333 333 333 333 333 333 333 333 333 333 250 200 125 125 125

Tyfo 450 450 450 450 450 450 450 450

0

50

100

150

200

250

300

350

400

450

500

Aegion Product Matrix by Maximum Internal Operating Pressure

Questions?

THANK YOU! Geoffrey Burdick, PERegional Sales Manager

TM