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GeoPolymer Mortar System for Structural Rehabilitation of Sewer and Storm Infrastructure

Founded in 1865, Milliken is one of the worlds largest privately held chemical and textile companies.

Today, Millikens products and people encompass the globe with over 7,000 associates working in more than 45 facilities worldwide, creating more than 19,000 products for our customers.

Headquartered in Spartanburg, SC, Milliken is recognized for global leadership in quality, safety, environmental excellence and innovation.

Milliken & Company

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2014 Milliken Infrastructure Solutions, LLC

45 Facilities Around the World

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Milliken & Company3

2014 Milliken Infrastructure Solutions, LLCGlobal, Diversified Manufacturer of textile products and chemicals ~7,000 associatesManufacturing in 6 countriesOperations throughout Americas, Europe and Asia3

You come in contact with Milliken products close to 50 times a day4

Fifty Times a DayIn Your Home

Making food storage containers clearMaking duct tape both strong and tearable.Making bathroom sinks, countertops, tubs and appliances anti-microbial.Making your mattresses fire-resistant.Making strong plastic parts in your household appliances.Adding color to detergents, sponges, bowling balls washable paints & markers.In household plastics, from laundry baskets to lawn furniture to drink cups.

In Retail

Making plastic packaging from caps to bottles to blister packaging - on store shelves clear or more colorful.

As retail floor coverings.

As fabric in store front banners and awnings.

At Work

In the infrastructure that delivers fiber optic cable.

In the military uniforms and industrial workwear that protect personnel.

As floor coverings for commercial, applications, schools, health centers, government buildings.When Traveling

As the floor coverings and fabrics in airports, hotels and restaurants.

In luggage.

In automotive airbags, tires, belts & hoses, trunks, and plastic parts.

At Play

Reducing odor and improving comfort in school sports gear, shoes and uniformsIn hunting garments.In helmets, playground equipment, watercraft and race car air dams .In restaurant table linens and food preparation areas.In boats and canoes.In Public Spaces

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Innovation that lets us do good for the world, create excellent experiences for our customers and build a sustainable business that allows us to innovate for the future.Our Legacy of InnovationInnovation has been core to Milliken since 1865.Innovation that brings together deep science, meaningful design and unique insights to bring a new approach to customer challenges.Innovation that reflects the creativity and passion of Milliken at our best.

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Milliken has been recognized as one of the World's Most Ethical Companies by Ethisphere Magazine every year since the first list in 2007. Ethics

2014 Milliken & CompanyMilliken GeoPolymers

What is a GeoPolymer?88Not a PlasticNot HDPE/PVC/Epoxy

Looks and feels like cementWorkabilityMaterial PropertiesService Life

Chemical structure like natural stoneMonolithicDurableCorrosion Resistant

2014 Milliken Infrastructure Solutions, LLC9GeoPolymer Chemistry PrimerTypical GeoPolymer ChemistryGeopolymers or alkali cements consist predominantly alumino-silicates or polymer Si-O-Al bonds and are similar in chemical make-up to natural Zeolites. Traditional starting materials for geopolymers cements are fumed silica, fly ash & metal slag.Geopolymers can be produced from commercially available industrial waste streams, creating a highly environmentally friendly product.

The chemical reactions of geopolymer create only a fraction of the CO2 emissions of standard cementitious materials.

Geopolymers have excellent chemical and thermal resistance and can essentially be considered engineered stone.

Typical Geopolymer StructureSource J. Davidovits - Geopolymer Chemistry and Applications, 3rd ed.

2014 Milliken Infrastructure Solutions, LLC10GeoPolymer ProductsGeoSpray OverviewEngineeredHigh flexural and bond strength.High early and ultimate strength.Adapts to any shape, including bends, curves, and angles.

Lower Total CostGenerally lower installation and operating costs compared with alternative methods (SPR/CIPP/Slipline).Less disruption to the communityFaster installation.SustainableLower greenhouse gas emissions.50%+ of raw materials come from recycled industrial by-products.Locally manufactured.

SafeStyrene FREE.Contains no leachable toxins.Passed EPA TCLP Toxicity Characteristic Leaching Procedure.

2014 Milliken Infrastructure Solutions, LLC11GeoPolymer ProductsGeoSpray Physical Properties

2014 Milliken Infrastructure Solutions, LLCGeoPolymer AdvantagesSelf BondingExperimental Parameters:

On the first day a series of 2 by 4 cylinders were cast half full and cured with on an approximately 45 angle.

On subsequent days (1, 7, 14 and 28) the top half of the cylinders were cast and filled creating a 45 angled joint in the center of the cylinders

Compressive strength tests were conducted 28 days after the top half of the cylinders were cast.

Joint in Tested Sample12

2014 Milliken Infrastructure Solutions, LLC13GeoPolymer AdvantagesSelf Bonding

Day 0Day 1Day 7Day 14Day 28GeoSpray

Day 0Day 1Day 7Day 14Day 28Leading Portland Based CompetitorResults:

Samples cast of GeoSpray (both halves) when tested under compression did not break at the joint.

The chemical nature of GeoSpray allows for chemical bonding across the interface even with pours 28 days apart resulting in a monolithic structure.

Samples cast of competitive cement mortars always broke along the angled joint essentially creating 2 separate layers.This unique property of geopolymers allows project flexibility in variable weather conditions as the covalent bonds prevent cold joint shear failure

2014 Milliken Infrastructure Solutions, LLC14GeoPolymer Products3rd Party Certified TestingC1138M Abrasion Resistance of Concrete (Underwater Method Additions)C779 Abrasion Resistance of Horizontal Concrete SurfacesC403 Time of Setting of Concrete Mixtures by Penetration ResistanceC1260 Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)C227 Potential Alkali Reactivity of Cement-Aggregate Combinations (Mortar-Bar Method)C114 Chemical Analysis of Hydraulic Cement C1543 Determining the Penetration of Chloride Ion into Concrete by PondingC1585 Measurement of Rate of Absorption of Water by Hydraulic-Cement ConcretesC642 Density, Absorption, and Voids in Hardened ConcreteC188 Density of Hydraulic CementC786 Fineness of Raw Materials by the 300-m (No. 50), 150-m (No. 100), and 75-m (No. 200) by Wet MethodsC1702 Measurement of Heat of Hydration of Using Isothermal Conduction CalorimetryC156 Water Loss [from a Mortar Specimen] Through Liquid Membrane- Forming Curing Compounds for ConcreteC597 Pulse Velocity Through ConcreteC900 Pullout Strength of Hardened ConcreteC136 Sieve Analysis of Fine and Coarse AggregatesC666 Resistance of Concrete to Rapid Freezing and ThawingC109 Compressive Strength of Hydraulic Cement Mortars (Using 2-in. or [50-mm] Cube Specimens)C1012 Method for Length Change of Hydraulic-Cement Mortars Exposed to a Sulfate SolutionC452 Potential Expansion of Portland-Cement Mortars Exposed to SulfateC39 Compressive Strength of Cylindrical Concrete Specimens C469 Static Modulus of Elasticity and Poisson's Ratio of Concrete in CompressionC496 Splitting Tensile Strength of Cylindrical Concrete SpecimensC512 Creep of Concrete in CompressionC78 Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading)C1064 Temperature of Freshly Mixed Hydraulic-Cement ConcreteC138 Density (Unit Weight), Yield, and Air Content (Gravimetric) of ConcreteC143 Slump of Hydraulic-Cement ConcreteC231 Air Content of Freshly Mixed Concrete by the Pressure MethodC191 Time of Setting of Hydraulic Cement by Vicat NeedleC157 Length Change of Hardened Hydraulic-Cement Mortar and ConcreteC1506 Water Retention of Hydraulic Cement-Based Mortars and PlastersC187 Amount of Water Required for Normal Consistency of Hydraulic Cement Paste

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2014 Milliken Infrastructure Solutions, LLCInstallation

16Structural Rehabilitation Centrifugal CastingCentrifugal Casting of GeoSprayRapidly distributes material within the pipes internal circumference Forms a strong, low permeability, cement mortar lining Depending upon design & thickness, creates a pipe within a pipe and does not rely on the integrity of the host structureWhile not generally required it is compatible with most common reinforcement technologies

2014 Milliken Infrastructure Solutions, LLC17Structural RehabilitationApplication Process17

2014 Milliken Infrastructure Solutions, LLC18Structural RehabilitationGeoPolymer Mortar Solutions

Wall thickness range 1.5-4Based upon specific design requirements

Centrifugally Cast Concrete Pipe (CCCP) employs a similar spin casting process as a non-structural mortar lining, but cementitious materials are applied to a thickness that creates structural integrity of a whole new pipe within the host structure.

2014 Milliken Infrastructure Solutions, LLCA family of cementitious geopolymer mortar products designed for use in the rehabilitation of pipes and structures in Chemical, Civil Infrastructure, Mining, and Oil & Gas industries.

Pipe RehabilitationStorm Water - CulvertsSewer WaterPotable Water

TransportationTunnels and BridgesRoads

Buildings and StructuresCommercialIndustrial

Milliken GeopolymersApplications

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2014 Milliken Infrastructure Solutions, LLC20GeoPolymer AdvantagesApplication Flexibility20

AnglesBends, curves, and change in elevationLateralsMonolithically tied to structureHost pipe materialBrick, Rock, ConcreteCorrugated Metal or Cast IronHost pipe conditionSlightly to fully deteriorated

2014 Milliken Infrastructure Solutions, LLC21GeoPolymer AdvantagesApplication Flexibility

21ShapeNon-round, elliptical, egg shapedManholes, wet-wells, junction boxesLengthShort lines, culverts, point repairLonger sewer and storm segmentsDiameterFrom 36 inches to 180 inchVarying diameter in a single runOvalityOvality greater than 10%Box culverts and structures

2014 Milliken Infrastructure Solutions, LLC22GeoPolymer AdvantagesEffective and EfficientLower total system cost than alternative methodsInstallation + ongoing operating costsPoint of failure repairLess risk exposure from weatherLess disruptive to the communityLess cost associated with road closures, non-productive labor, traffic delays, impact to local business, etc.More quickly implementedLess cure/set-up time

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2014 Milliken Infrastructure Solutions, LLC