smart lining for pipes and infrastructure€¦ · smart lining for pipes and infrastructure. 2b ....

The University of Sydney 36

Smart lining for pipes and infrastructure

2B Wastewater CRCP Roadshow

October-November 2019

A/Professor Marjorie ValixSchool of Chemical and Biomolecular EngineeringFaculty of Engineering and IT

This presentation is for individual reference only, do not reproduce materials or publish without permission from WSAA.

The University of Sydney Page 137

Agenda

1. Management of Sewer Infrastructure2. Aims3. Approach/Schedule

• Field Test (up to 2.5 years)• Excavation (service life > 3 years)• Accelerated Corrosion Tests

4. Learning Modules5. Overall Schedule


Management of Sewer Infrastructure

Mitigation Strategies

• Renewal costs high- e.g., $5000/m

• Rehabilitation is therefore preferred

• Many available mitigation technologies –e.g., coatings but uptake has been slow

• Lack of streamlined regulations and compliance requirements

• Lack of verified performance in Australia

Critical services vital to the sustainability of our cities

Challenges• Extensive • Buried under other assets -

difficult to access• Hazardous - (H2S -toxic),

(CH4 flammable)• Acid attack or ‘MICC’• Ageing, most at end of life

Replace or Extend the Life?


Addressing these challenges through the CRC-P

To develop rehabilitation decision tools for effective use of coatings in extending the life of sewer infrastructure

To translate learnings into educational modules

AIMS

Unique Partnership


Coatings

CaO

SiO2

Al2O3

OPC

Geopolymer

CAC

• Higher acid neutralization capacity (ANC) and lower porosity compared to OPC

• Biocidal property - release of toxic Al3+ ions • Buffering effect of Al(OH)3 precipitate - maintain CAC surface

to pH 3-4 - controls acidophilic bacterial growth.• CAC performance unaffected by high humidity

• Lower Ca and polycondensation phase (rather than hydration)– higher corrosion resistance and less permeable compared to OPC

• Green concrete- lower CO2 footprint• Higher ANC – controls bacterial growth• Lighter compared to OPC


Approach

Field Testing of Coatings

(<3 years)

Excavation of Coatings in

Service for >3 years)

Accelerated Corrosion Tests

2B Wastewater

‘Live’ sewer tests

Lab tests

• Coating Performance Knowledge • Decision Tools• Learning Modules


(I) Field Testing

Condition Assessment of

Asset

Surface Preparation

Coating Application

Monitoring

Reinstatement

Direct application of coatings on ‘live sewers’ = capturesapplication requirements + corrosion resistance1

2

3

4

5


Field Tests Participants & Location Field Testing of

Coatings(<3 years)

Excavation of Coatings in

Service for >3 years)


PipeAccess Chamber

UK

5x

5x

4x

4x

https://sydney.edu.au/


https://www.watercorporation.com.au/


https://www.sawater.com.au/

https://www.sawater.com.au/

http://www.sydneywater.com.au/


https://www.urbanutilities.com.au/

https://www.urbanutilities.com.au/

https://www.melbournewater.com.au/

https://www.melbournewater.com.au/

https://www.interflow.com.au/







Coating Manufacturer Partners

Geopolymers

Calcium Aluminate Cements (CAC)

> 8 coatings (5 CAC, 3 Geopolymers), 1 control being tested in 17 assets with 88 coating trials for up to 2.5 years

https://www.calucem.com/home.html

https://www.calucem.com/home.html



http://www.milliken.com/

http://www.milliken.com/


Condition Assessment of Assets/Coatings in Service

Man- Entry Pipes (> 2.0 m)

Access Chambers (1.0 m ID x 1-3 m

deep)

Pipes (2-3 m ID)

Surface pH

Porosity

Compressive Strength

Depth of Corrosion

2 x cores (top, bottom)/manhole

2 -3 cores (crown, wall and tidal/5-10 m)

• Asset History• Asset Environmental

Conditions

Condition Assessment

Corrosion Classification

1


Surface Preparation

0

2

4

6

8

10

12

14

0 5 10 15 20

pH

mM H+ / g sample

ANC-OPC PhenolpthaleinpH < 8.0: colourless

pH > 8.0: pink

Universal indicator

Using pH dye indicators to gauge required surface pH

Depth of Acid Permeation

Corroded

Less-Corroded

Acid Neutralisation Capacity

2


Coating Application and Monitoring

0

50

100

150

200

250

300

350

400

450

500

0.08 0.1 0.12 0.14 0.16 0.18 0.2

Init

ial S

ett

ing

Tim

e (

min

)

Water/Concrete Ratio

Initial Setting Time -CAC

A B C D E F G

4 hours return to service

4

2000

2050

2100

2150

2200

2250

2300

2350

2400

2450

2500

0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.22

De

nsi

ty (

Kg

/m3)

W/C Ratio (kg/kg)

Calcium Aluminate

SewerCem Pro (Sewer Mix 1)

SewerCem Eco-2 (Sewer Mix 3)

Extrema-Dur® S3 (EDS3)

BASF (Master Emaco S680)

Bisley (Extrema Dur S1)

Placement Propertiese.g., setting times Water to Concrete Ratio


Coating Application and Monitoring – Pipes

1000 mm

1500 mm

Tidal

WallRoof

CAC(CAA)

OPC Concrete

CAC(CAA)

OPC Concrete

CAC(CAA)

OPC Concrete

CAC(CAA)

OPC Concrete

CAC(CAA)

OPC Concrete

CAC(CAA)

OPC Concrete

Frequency of monitoringPost installation, ~ 6-8 months (3x for the duration of the program)

Application

50 cm border

2 m

Environmental MonitoringH2S, CO2, etc

TRH

Infiltration

coatings Uncoated

Pipe

Sampling

Shotcrete Control

2 m

3,4

Monitoring


Coating Application and Monitoring – Maintenance Holes

1.9 m

Test area

1.2 m

Cores

CAC(CAA)

OPC Concrete

CAC(CAA)

OPC Concrete

4

Application

Frequency of monitoringPost installation, ~ 6-8 months (3x for the duration of the program)

Monitoring


Coating Application and MonitoringMeasuring Thickness of the Coatings

Coating

Host

Ni-Ag Rebars

4


Coating Application and MonitoringThickness Measurement Post Application

Embedded Ni-Ag Sensor

4

Pipes (2-3 m ID)


Coating Application and Monitoring Example of the Process of Coating Application

2 431

109876

5

4

Condition Assessment


Coating Application and Monitoring Schedule

M A M J J A S O N D J F M A M J J A S O N D J F M M A M J J A S O N D J F

Trial Site Type ApplicatorsMelbourne Water Pipe Abigeldie

Sydney Water Pipe Interflow

Water Corporation Access Chamber Interflow

SA Water Access Chamber Interflow

QUU Access Chamber Veolia

Coating Application

2018 2019 2020 2021

MonitoringReinstatement

Condition Assessment of Asset

Reinstating Asset

Coating ApplicationMonitoringReinstating Asset

Condition Assessment of Asset Surface Preparation

MonitoringReinstating Asset

Condition Assessment of Asset Test BedSurface PreparationCoating ApplicationMonitoring

Coating Application

Surface PreparationCoating ApplicationMonitoringReinstating Asset


Coating ApplicationMonitoring

Condition Assessment of Asset


Reinstating Asset

6 months

5 months

8 months

7 months

6 months

6 months6 months

5 months 5 months

8 months 8 months

7 months 7 months

6 months 6 months

4


(II) Coating (3+ years old) Excavation

Coring of sewer wall

Wet Wells

Access Chambers

Pipes (2-3 m ID)

CAC(CAA)

OPC Concrete


Field Excavation Participants & Location Field Testing of Coatings(<3 years)

Excavation of Coatings in Service for >3 years)

Accelerated Corrosion

Tests

UK

Pipe

Access Chamber








Partners and Schedule for Coating Excavation

Bisl

ey

Calu

cem

Calu

cem

Inte

rflo

w

Parc

hem

BASF

Inte

rflo

w

Parc

hem

Mill

iken

Blue

ys

Ixom

Hych

em

Parc

hem

Inte

rflo

w

Trial Site Asset Type Extr

ema-

Dur S

1

Sew

erCe

m P

ro

Sew

erCe

m E

co-2

Inte

rche

m C

AC

Sew

perc

oat

Mas

ter E

mac

o S6

80

Qua

dex

Geo

kret

e

Rend

eroc

Geo

spra

y

BluC

em Z

eoG

lass

Sulf

aloc

k H

iGel

Hyc

hem

TL5

ELS

Epox

y

PVC

CIP

P

Sydney Water Pipe 4 2 10 4 4 24 Oct-19 StartedWater Corporation Pipe 3 3 Oct-19 Not startedWater Corporation Pipe 3 3 Oct-19 Not startedSA Water Access Chamber 2 2 Oct-19 Not startedSA Water Access Chamber 2 2 Oct-19 Not startedSEW Wet well 12 12 Apr-18 CompletedSEW Wet well 2 2 July Not startedIcon Water Pipe 2 2 May 1 2018 CompletedIcon Water Pipe 2 2 May 1 2018 CompletedIcon Water Pipe 2 2 May 1 2018 Completed

Hunter Water Pipe 1 1 Sep-18 Completed





Hunter Water Pipe 1 1 Oct-19 Not startedManufacturers 0

TOTAL 4 0 0 2 19 0 0 4 0 0 2 14 5 0 60

Stat

us

CAC Geopolymer Polymer

TOTA

L

Sche

dule

d


(III) Accelerated Corrosion Tests

– Product Testing Protocol

– Test Beds– Humidity Chamber– CO2 Chamber– Acid Corrosion

Chamber– Infiltration – Adhesion Testing

Facilities

Acid and Gas Phase Corrosion of Coating

Adhesion of Coating to Host Structure

Soil Corrosion and Infiltration

Functional, programmable properties of concrete (e.g., corrosion resistance, bacteriostatic, self-healing)

3,4

56

7

1

2


Product Testing Protocol

Porosity (Tomography, water

absorption, SEM)

Chemical

Mineralogical

Placement

StructuralAdhesion

Textural

Physical

• Elemental composition (XRF)• Extent of hydration (FTIR)• Depth of corrosion (microscopy, SEM-EDS)

• Composition • hydration reactions• corrosion reactions

and other reactions TGA, XRD

• Setting time• slump(workability)• rebound

Unconfined compressive strength

Bond Strength

• Weight• Dimension• Bulk Density

50.80 mm

0 mm

1


Test Beds - CO2 Chamber2

S

TempHum

% CO2Time

Control Unit (HMI)

Water Reservoir

Water Drain valve

To Exhaust

Water Level indecator

Heating System(Air Duct)

Gas-DoorSafety Lock

Gas Cylinder(CO2)


Test BedsCorrosion Chamber

2

Pa

pH

Gas Train

TI

Filling Pump

Temp, Press, Humidity

Water Trap

Acid-Sediment Drain Valve

Gas Cylinder

Acid Reservoir

Ventilation Fan

To Exhaust

TempPapH

% CO2

Control Unit (HMI)

TIPapH

Solenoid ValveDosing Pump

S


Test BedsInfiltration and Adhesion

2

Pressurisedwith air

(water, SO42-

or Cl- )

Substrate (Concrete or

Coatings)

Drain


Geopolymer /Calcium Aluminate Concrete Accelerated Corrosion Tests

Field Test

Establish Mechanisms of Corrosion


Develop Test Beds

Develop Protocol for Corrosion Test (e.g., types of acids and

other conditions)

Establish Microbial Activity and Type of Acid Corrodents

Accelerated Corrosion Method (verified from coating performance in the field)

3,4

Establish Corrosion Classifications

• Verify Relative Performance of Coatings (data for service model(s)• Establish Impact of Defects on Coating Performance• Establish Impact of Coating Reactions (e.g., conversion, efflorescence) on

Coating Performance


Adhesion5

Field Test

Systematic Testing of Parameters

LabTests

(1) Structural properties of host

(2) Extent of host corrosion

Bond strength

Cohesive failure of host

Cohesive and Placement failure of coating

Corroded section

(5) Coating corrosion and sulphate resistance (expansive products)(6) Dry Shrinkage/Expansion

(4) Structural properties of coating

(3) Surface preparation and properties

Verification

• Model(s) to predict adhesive durability of coatings• Establish impact of host conditions and surface preparation on coating

adhesion• Establish impact of coating corrosion on adhesion behaviour


Infiltration and Soil Corrosion6

Impact of Infiltration on Adhesion

Kinetics of Soil and Infiltration Head Pressure Induced Corrosion

Field Test LabTests

Corrosion Kinetics of Coatings from Infiltration


Verification


Programmable Concrete PropertiesTo determine iteratively the coating composition and functionalities to promote coating durability under the different sewer corrosion categories in the short and long term.

Acid Permeation

(6) Design thickness(7) Functionalities (e.g., bacteriostatic effects)

“ Sewer Corrosion Categories”

(1) Coating composition (e.g., alkalinity, binder/aggregate, pozzolan, C3A)

(2) Porosity(pore volume, pore size distribution)

(5) Abrasion resistance

(4) Chemical resistance

(3) Mineral transformations (e.g., conversion)

7

Field Test LabTests


Verification


Learning Modules

3D Videos 2D Videos CCTV Photos

LearningEducation Modules


Staff and Students (updated)

Staff Students Required Current

Research Assistant 1.0-1.5 0.5

Senior Research Engineer 1 0.2

PG Students 4 5


General Schedule Updated

No 2B General Milestones Activities/Deliverables 2021Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1

Literature Review2B.1 Wastewater Testbed

2B.2 Product Testing Protocol

Placement Testing

Structural AnalysisCondition AssessmentField TestingLab Testing

2B.5 Failure Modes1B Decision Tools Pipe Prioritisation Criteria

Sewer Corrosion CategoriesCoating Selection Guidance-Adhesion + PlacementCoating Selection Guidance-Chemical ResistanceService Life Model(s)

QA/QC for Coating Application4B Education Modules

Coating Performance2B.4

2018 2019 2020

Installation Factors2B.3

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