pacific northwest section, awwa vancouver 2008 conference fusible polyvinylchloride pipe: expanding...

Pacific Northwest Section, AWWA Vancouver 2008 Conference Pacific Northwest Section, AWWA Vancouver 2008 Conference

Fusible Polyvinylchloride Pipe: Expanding Thermoplastic Fusible Polyvinylchloride Pipe: Expanding Thermoplastic Trenchless Applications and BeyondTrenchless Applications and Beyond

May 2May 2ndnd, 2008, 2008

Richard (Bo) Botteicher, Richard (Bo) Botteicher, PEPE

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Fusible Polyvinylchloride Pipe - Fusible PVC ™Fusible Polyvinylchloride Pipe - Fusible PVC ™

Where has this stuff been??– Technology developed to create a close-fit “C909”

slipline rehabilitation solution– Thermal fusion was used to join pipe lengths

together– The fusion technology was then developed and

refined as a stand-alone technology– Fusible PVC™ procedure requires appropriate pipe

and the proper fusion procedure

Where is it going?– More than 500 successful projects installed to date– Projects in over 34 states, Canada and Mexico

®

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Fusible Polyvinylchloride Pipe Technology OverviewFusible Polyvinylchloride Pipe Technology Overview

Fusible Polyvinylchloride Pipe Technology– Formulation– Fusion Procedure

Design– Water Systems– Connections– Trenchless Construction

Installation Options– Trenchless Techniques– Direct Bury / Traditional Techniques– Case Studies

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Fusible PVC™ TechnologiesFusible PVC™ Technologies

Two significant developments were required to produce Fusible Polyvinylchloride Pipe:

– Formulation for PVC extrusion.

– Butt-fusion procedure.

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• Meets requirements of ranges for components designated in PPI-TR2.

• NSF-61 certified.

• Meets ASTM Cell Classification 12454 – Industry Standard PVC Plastic for water and wastewater use.

FormulationFormulation

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PVC Classification and CompliancePVC Classification and Compliance

PPI-TR2

ASTM D1784Cell Class 12454

Range Formulation for PVC Pipe

Calculates HDB For Plastic Pipe

PPI-TR3

Hydrostatic Design Basis of 4000 psi

AWWA C900/905

Requires PPI-TR3, ASTM D1784 CellClass 12454, NSF 61

Minimum StandardsFor Drinking Water

PVC Pipe

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• Uses standard thermal fusion equipment.

• Equipment readily available within infrastructure construction industry.

• Pressure, temperature, and time (duration of each step) unique to PVC.

• Process time approximately the same as HDPE.

Fusion ProcedureFusion Procedure

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PVC Fusion Process: Utilizes Industry Standard Fusion EquipmentPVC Fusion Process: Utilizes Industry Standard Fusion Equipment

Internal and External Bead Removal is Optional – friction losses are negligible (‘C’-factor of 150) andare significantly less than mechanically joined pipe (i.e. for 8” DR18 with 1000gpm in a length of 1000LF, flow loss is 0.173 gpm and a head loss of 0.013 ft) and pipe tensile strength is not impaired (extra material in bead)

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Fusible PVC™: Fusion Process Is Tightly ControlledFusible PVC™: Fusion Process Is Tightly Controlled

Qualified fusion technicians are trained and must be retrained every year

– Initial 3 day course

Fusion equipment must meet minimum 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)

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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

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Joint StrengthJoint Strength

• Hauser Labs, Boulder, CO has performed 3rd party testing.

• Testing to date includes tensile strength, flattening, acetone immersion column buckling, 3-point bending, and burst testing, among others.

• Tensile tests performed on 1000’s of samples in sizes from 4” to 36”

• Results representative of full pipe strength.

Fused Joint

®


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Fusible PVCFusible PVCTMTM is the Most Tested PVC Pipe in the Industry with Four Levels is the Most Tested PVC Pipe in the Industry with Four Levels of Quality Control to Help Ensure Flawless Installationsof Quality Control to Help Ensure Flawless Installations

Test VendorQualification

Required VendorTesting

UGSI LotAcceptanceTesting

Fusion Joint QCData

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

HydrostaticPressure Test

Per AWWA C900/C905

Per AWWA C900/C905

Impact Test ASTM D2241;ASTM D2444

ASTM D2241;ASTM D2444

Heat Reversion ASTM F1057 ASTM F1057 ASTM F1057

Ash/Inert Content(LOI)

ASTM D2584 ASTM D2584Per UGSI Request

Joint FusionParameters

TemperaturePressure, Location,Other

Licensed Operator Unique Operator ID

Note: Bold highlights indicate required AWWA tests ®

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Independent Laboratory Testing: Prior to Acceptance for ProjectsIndependent Laboratory Testing: Prior to Acceptance for Projects

Flattening Test:

– Pipe compressed to 40% of specified O.D. with no splitting, cracking or breaking

Extrusion Quality Tests:– Acetone Immersion: Poor fusion

quality (fusion of resin mix) is evident when flaking and disintegration is displayed

– Heat Reversion: A number of fail conditions including excess moisture and poor vacuum control on the extrusion line – as exhibited by blistering or wall separation

FlatteningPass

Flattening Fail

Heat Reversion

Fail

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Designing Water System Infrastructure with Fusible PVC™Designing Water System Infrastructure with Fusible PVC™

Identical PVC Plastic…– ASTM D1784 – for PVC plastic Cell

Classification (12454)– NSF 61 certified– AWWA C900 & C905 compliant– IPS, and Schedule sizing available as

well– Available in white and purple colors as

well

New Joining Technique…– Thermal butt fusion joints provide the

same strength as the pipe wall.– No gaskets.– No exfiltration or leakage.– No over-deflection, over-seating, or

rolled gaskets possible at joints. – Compatible with raw water sources –

brackish water, high solids content, etc.

Distribution and Raw Water Piping

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Designing Water System Infrastructure with Fusible PVC™Designing Water System Infrastructure with Fusible PVC™

Critical Infrastructure– Under rivers, major streets and other

problem areas– Will not leak at joints– Fully restrained at joints– May eliminate bends and some fittings– Very good contamination resistance,

including gasoline

Repair and Maintenance– Standard waterworks repair fittings for

PVC pipe– Standard industry knowledge– No special equipment needed– No specialized training needed

Design of Critical Pressure Piping and Ongoing Maintenance

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Designing Water Systems - Restrained JointDesigning Water Systems - Restrained Joint

Conventional Gasketed & Restrained PVC to PVC Connections12” Example

Fusible C-900®, Fusible C-905®®, FPVC™ Low Profile Restrained Joint

TerraBruteTM

Barrel = 13.2”Bell = 16.75”

Certa-LokTM

Barrel = 13.2”Bell = 15.83”

Barrel = 13.2”Bell = 16.75”

Restraining Hardware = 19.45”

Barrel and Fused Joint Have Consistent O.D. = 13.2” ®

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Designing Water Systems - Industry standard couplings and Designing Water Systems - Industry standard couplings and fittings for connections and reconnectionsfittings for connections and reconnections

Connecting to Fittings

Mechanical Joint Fittings:

Flanged Joint Fittings:

Connecting to Pipe

Same Piping Size:

Different Piping Size:

Pictures from various manufacturers of fittings: JCM, Smith Blair, EBAA Iron, Romac Industries, American Pipe.

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Designing Pressure Piping Infrastructure with Fusible PVC™Designing Pressure Piping Infrastructure with Fusible PVC™

Horizontal and Vertical Layout – uses standard line and grade installation

Three additional Design Factors:– Allowable Bend Radius– Tensile Capacity of PVC Plastic– Thermal Expansion and Contraction

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Trenchless Installation and Rehabilitation Methods May Trenchless Installation and Rehabilitation Methods May Dramatically Reduce Project CostsDramatically Reduce Project Costs

Traditional Direct-Bury, Open-Cut or Exhume & Bury pipe installation methods can be disruptive, impractical and limiting – especially in rehabilitation efforts

Trenchless methods reduce:– Project costs– Business interruption costs– Political costs

An estimated 25% of water line rehabilitation is done utilizing trenchless technologies

Hard Project Costs are Potentially Reduced Hard Project Costs are Potentially Reduced by 20-40% through use of Trenchless by 20-40% through use of Trenchless

MethodsMethods

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Installation Design with Fusible PVC™Installation Design with Fusible PVC™

Existing System Rehabilitation or Alternative Installation Techniques Available– Pipe Bursting and Sliplining Rehabilitation– Horizontal Directional Drilling

Utilizes the Tensile Capacity of the PVC Plastic, Bend Radius and consistent Outer Diameter of the pipe

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HDD Design Considerations with Fusible PVC™HDD Design Considerations with Fusible PVC™

No relaxation period required – immediate connections possible

Higher density of Fusible PVC™ reduces buoyant forces to reduce pull-in forces

The favorable PVC plastic weight to tensile strength ratio allows longer, higher pressure installation by HDD, between steel pipe and HDPE pipe

5,120 ft 10” DR14 pulled in a single continuous drill operation

4,400 ft 24” DR 18 pulled in a single continuous drill operation

HorizontalHorizontalDirectionalDirectional

DrillingDrilling


DrillingDrilling

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HDD Design Considerations with HDD Design Considerations with Fusible PVC™Fusible PVC™

® Pit Layout and Design


DrillingDrilling


DrillingDrilling

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Horizontal Directional Drilling with FPVCHorizontal Directional Drilling with FPVCTMTM - -

Broomfield, COBroomfield, CO

2,420 linear feet of FPVC™

24” DR25 FPVC™ purple pipe for reclaim water line

Client: City and County of Broomfield, COHorizontalHorizontalDirectionalDirectional

DrillingDrilling


DrillingDrilling

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Horizontal Directional Drilling with FPVCHorizontal Directional Drilling with FPVCTM TM - Beaufort, SC- Beaufort, SC

5,120 linear feet of 10” DR 14 FPVC™

Longest pull of thermoplastic pipe in the water & wastewater industry

Client: Beaufort Jasper Water & Sewer Authority for Secession Golf Course


DrillingDrilling


DrillingDrilling

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Insertion SideInsertion Side

Beaufort River Crossing AlignmentBeaufort River Crossing Alignment

All mapping provided by Google®

Drill SideDrill Side

Beau

fort

Riv

er

Beau

fort

Riv

erB

eauf

ort R

iver

Bea

ufor

t Riv

er

Secession Secession Golf CourseGolf Course

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Project consists of 60,000’ of 24” water main in 4 divisions

Supply from CWS through St. John's Water Company system to wholesale users

19,000’ designed as HDD, including 4,260’ under the Stono River

4,400’ of 24” DR18 Fusible C-905® laid out

Client: St. John’s Water Company Stono River Crossing (Div. IV)


DrillingDrilling


DrillingDrilling

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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 of 150 with internal

bead

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Slipline Design Considerations with Fusible Slipline Design Considerations with Fusible PVC™PVC™SlipliningSlipliningSlipliningSliplining

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Slipline Design Considerations with Fusible Slipline Design Considerations with Fusible PVC™PVC™

Cleaning and video inspection recommended to ensure acceptable clearance prior to insertion

Recommended difference between ID of host pipe and OD of Fusible PVCTM is 2” at a minimum

Grouting or other treatment of annular space is advised

– Eliminate void space, nuisance water, and potential future collapse around new sliplined pipe

– Fully support and fix new sliplined pipe in place This process can be employed with new casings

– Casing spacers may be utilized– Annular space treatment may be utilized

Fusion may be done in the access pit 3,510 ft 12” DR18 pulled in one operation

SlipliningSlipliningSlipliningSliplining

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Slipline Design Considerations with Slipline Design Considerations with Fusible PVC™Fusible PVC™SlipliningSlipliningSlipliningSliplining

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Pit Layout and Design

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Client: United Water

Sliplining with Fusible C-900Sliplining with Fusible C-900®® – Harrisburg, PA – Harrisburg, PA

3,510 linear feet of Fusible C-900®

Host Pipe – 16” cast iron

12” DR 18 for water line under the Susquehanna River


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Client: Horseshoe Construction for Zaragosa Boulevard

Sliplining with Fusible C-905Sliplining with Fusible C-905®® – El Paso, TX – El Paso, TX

16,300 linear feet of Fusible C-905®

Host Pipe – 36” Prestressed Concrete-Lined Cylinder Pipe (PCCP)

24” DR25 for water line under Zaragosa Boulevard


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Client: Horseshoe Construction for Zaragosa Boulevard

Businesses along Zaragosa Rd remained open with minimal access issues

Texas Council of Engineering Companies 2008 Silver Medal Award winner


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Static Hydraulic Method is used Typically done in 300 - 500’ increments (~1 hour pull-back) Utilizes existing alignment – less engineering cost to locate adjacent

utilities

Fusible PVCTM

Pipe Bursting Design Considerations with Pipe Bursting Design Considerations with Fusible PVC™Fusible PVC™

PipePipeBurstingBurstingPipePipe

BurstingBursting

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Ductile iron, cast iron, asbestos-concrete and steel are typical water pressure pipe materials that are burst – high production rates are possible (recent project in Florida - 500 LF in 1 hour)

Static hydraulic bursting/splitting method is used vs. pneumatic method (typically used in sewer work)

High density and hardness of Fusible PVCTM results in excellent scratch and abrasion resistance

Isolation of pipe from burst hardware prevents rebound when force changes rapidly

Pre-chlorination method – removes need for bypass line installation – required disinfection is done above ground prior to burst/pull-in (24 hour sampling per AWWA)

– Pits for lateral connections dug prior to pull-in– Once new pipe is pulled-in, laterals are connected using standard PVC

tapping and connection techniques– 20% less cost than dig-and-replace


BurstingBurstingPipe Bursting Design Considerations with Pipe Bursting Design Considerations with

Fusible PVC™Fusible PVC™

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Ypsilanti, MI Ypsilanti, MI

M-17 (Ecorse Road) Water Main Replacement Project

8”,12”, and 16” Water Main Pipe Bursts8”,12”, and 16” Water Main Pipe Bursts


BurstingBursting

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Project Details

800 LF of 16” 5200 LF of 12” 2000 LF of 8”

Pre-fused Fusible PVC™ by Midwest Trenchless

Pre-fused lengths for pulls ranged:– 780 LF down to– 320 LF

Ypsilanti, MI - M-17 Water Main Replacement Project


BurstingBursting

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Sample Installation Sequence



BurstingBursting

®

1. 3.2.

5.4.

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Potable Water Mains Michigan DOT and Michigan DEQ

approvals required Pre-chlorinated Pipe Bursting and

Horizontal Directional Drilling



BurstingBursting

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Results Successfully installed and tested Minimized public impact

– Minimal traffic closure– Minimal commercial impact



BurstingBursting

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Fusible PVCFusible PVCTMTM is an efficient and elegant leak-free design in open-trench is an efficient and elegant leak-free design in open-trench installation, and also delivers a fully restrained, corrosion free jointinstallation, and also delivers a fully restrained, corrosion free joint

Open-Trench/Open-Trench/Direct BuryDirect Bury


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Direct Bury with FPVCDirect Bury with FPVCTMTM – Naples, FL– Naples, FL

33,000 LF of 30”, 24”, 16”, 12”, 8” FPVCTM

Raw water collection system for 12 MGD brackish water RO Facility

Client: Collier County, FL Open-Trench/Open-Trench/Direct BuryDirect Bury


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Direct Bury with Fusible C-900Direct Bury with Fusible C-900®® – Sunnyvale, CA – Sunnyvale, CA

4,200 LF Direct Bury

12” DR18 Fusible C-900® for new water line

Towne Center ProjectPotable Water LineDirect Bury/HDDDirect Bury/HDDDirect Bury/HDDDirect Bury/HDD

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Selected National A&E Firms Specifying Fusible C-900™/Fusible C-905Selected National A&E Firms Specifying Fusible C-900™/Fusible C-905®®/FPVC™ /FPVC™

Arcadis Army Corp of Engineers Austin Civil GroupBanner AssociatesBartlett –WestBKFBolton-MenkBonestrooBowen-CollinsBP BarberBrelje and RaceBrown and CaldwellCarolloCarter and BurgessConklin, Porter and HolmesCDMCH2M HillDudekEarth TechGC Wallace

Greeley And HansenHarris and AssociatesHDRInterstate EngineeringKennedy JenksKimley-HornMetcalf and EddyMWHMoore EngineeringNolte Assoc. Parsons EngineeringRBFRMC WaterStantecPBS&JTetra TechWinzler and KellyWilson & CompanyURSUtility Services

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Fusible Polyvinylchloride Pipe for Water System PipingFusible Polyvinylchloride Pipe for Water System Piping

Fusible Polyvinylchloride Pipe Technology requires:– PVC piping that can create integral, full-strength

fusion joints– The correct fusion procedure

Water System Design will benefit from:– Tough, reliable, accepted PVC thermoplastic

material – Leak free pipe system– Integral restrained joint– Acceptance of standard PVC/DIP fittings and

methods Suitable for varied and demanding Installation

Techniques– Horizontal Directional Drilling– Sliplining Rehabilitation– Pipe Bursting– Direct Bury

®

Questions?Richard (Bo) Botteicher, PE

(303) 521.2618

Underground Solutions, Inc.Poway, CA

www.undergroundsolutions.com858-679-9551

pacific northwest section, awwa vancouver 2008 conference fusible polyvinylchloride pipe: expanding...

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