Pacific Northwest Section AWWA Vancouver 2008 Conference Fusible

Pacific Northwest Section, AWWA Vancouver 2008 Conference Fusible Polyvinylchloride Pipe: Expanding Thermoplastic Trenchless Applications and Beyond May 2 nd, 2008 Richard (Bo) Botteicher, PE

Fusible Polyvinylchloride Pipe - Fusible PVC ™ · Where has this stuff been? ? – Technology developed to create a close-fit “C 909” 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 ® 2

Fusible 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 ® 3

Fusible PVC™ Technologies · Two significant developments were required to produce Fusible Polyvinylchloride Pipe: – Formulation for PVC extrusion. – Butt-fusion procedure. ® 4

Fusible PVC™ Technologies Formulation • Meets requirements of ranges for components designated in PPI-TR 2. • NSF-61 certified. • Meets ASTM Cell Classification 12454 – Industry Standard PVC Plastic for water and wastewater use. ® 5

PVC Classification and Compliance Range Formulation for PVC Pipe PPI-TR 2 ASTM D 1784 Cell Class 12454 Calculates HDB For Plastic Pipe PPI-TR 3 Hydrostatic Design Basis of 4000 psi Minimum Standards For Drinking Water PVC Pipe AWWA C 900/905 Requires PPI-TR 3, ASTM D 1784 Cell Class 12454, NSF 6 ® 6

Fusible PVC™ Technologies Fusion Procedure • 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 ® 7

PVC Fusion Process: Utilizes Industry Standard Fusion Equipment Internal and External Bead Removal is Optional – friction losses are negligible (‘C’-factor of 150 are significantly less than mechanically joined pipe (i. e. for 8” DR 18 with 1000 gpm in a length of 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) ® 8

Fusible 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 data for 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 ® 9

Fusible PVC™ Technologies Joint Strength • Hauser Labs, Boulder, CO has performed 3 rd party testing. • Testing to date includes tensile strength, flattening, acetone immersion column buckling, 3 -point bending, and burst testing, among others. Fused Joint • Tensile tests performed on 1000’s of samples in sizes from 4” to 36” • Results representative of full pipe strength. ® 10

Fusible PVCTM is the Most Tested PVC Pipe in the Industry with Four Levels of Quality Control to Help Ensure Flawless Installations Test Vendor Qualification Required Vendor Testing UGSI Lot Acceptance Testing Fusion Tensile ASTM D 638 Pipe Dimensions Per AWWA C 900/C 905 Pipe Burst Per AWWA C 900 Flattening Per AWWA C 900/C 905 Acetone Immersion ASTM D 2152 Hydrostatic Pressure Test Per AWWA C 900/C 905 Impact Test ASTM D 2241; ASTM D 2444 Heat Reversion ASTM F 1057 Ash/Inert Content (LOI) ASTM D 2584 Per UGSI Request Fusion Joint QC Data ASTM F 1057 Joint Fusion Parameters Temperature Pressure, Location, Other Licensed Operator Unique Operator ID Note: Bold highlights indicate required AWWA tests ® 11

Independent Laboratory Testing: Prior to Acceptance for Projects · Flattening Test: – Pipe compressed to 40% of specified O. D. with no splitting, cracking or breaking Flatteni ng Fail · 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 Flattening Pass Heat Reversion Fail ® 12

Designing Water System Infrastructure with Fusible PVC™ Distribution and Raw Water Piping · Identical PVC Plastic… – ASTM D 1784 – for PVC plastic Cell Classification (12454) – NSF 61 certified – AWWA C 900 & C 905 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. ® 13

Designing Water System Infrastructure with Fusible PVC™ Design of Critical Pressure Piping and Ongoing Maintenance · 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 ® 14

Designing Water Systems - Restrained Joint Conventional Gasketed & Restrained PVC to PVC Connections 12” Example Barrel = 13. 2” Bell = 16. 75” Restraining Hardware = 19. 45” Terra. Brute. TM Barrel = 13. 2” Bell = 16. 75” Certa-Lok. TM Barrel = 13. 2” Bell = 15. 83” Fusible C-900®, Fusible C-905®, FPVC™ Low Profile Restrai Barrel and Fused Joint Have Consistent O. D. = 13. 2” ® 15

Designing Water Systems - Industry standard couplings and fittings for connections and reconnections Connecting to Fittings Connecting to Pipe Mechanical Joint Fittings: Same Piping Size: Flanged Joint Fittings: Different Piping Size: Pictures from various manufacturers of fittings: JCM, Smith Blair, EBAA Iron, Romac Industries, American Pipe. ® 16

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 ® 17

Trenchless Installation and Rehabilitation Methods May Dramatically Reduce Project Costs Hard Project Costs are Potentially Reduced by 20 -40% through use of Trenchless Methods · 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 ® 18

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 ® 19

Horizontal Directional Drilling 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” DR 14 pulled in a single continuous drill operation · 4, 400 ft 24” DR 18 pulled in a ® 20

Horizontal Directional Drilling HDD Design Considerations with Fusible PVC™ · Pit Layout and Design ® 21

Horizontal Directional Drilling with FPVCTM Broomfield, CO Horizontal Directional Drilling Client: City and County of Broomfield, CO · 2, 420 linear feet of FPVC™ · 24” DR 25 FPVC™ purple pipe for reclaim water line ® 22

Horizontal Directional Drilling with FPVCTM - Beaufort, SC Horizontal Directional Drilling Client: Beaufort Jasper Water & Sewer Authority for Secession Golf Course · 5, 120 linear feet of 10” DR 14 FPVC™ · Longest pull of thermoplastic pipe in the water & wastewater industry ® 23

Insertion Side Secession Golf Course er v i R t for u a e B Be au for t. R ive r Beaufort River Crossing Alignment Drill Side All mapping provided by Google® ® 24

Horizontal Directional Drilling Client: St. John’s Water Company Stono River Crossing (Div. IV) · 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” DR 18 Fusible C 905® laid out ® 25

Sliplining Slipline Design Considerations with Fusible PVC™ · 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 ® 26

Sliplining Slipline Design Considerations with Fusible 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 ® 27

Sliplining Slipline Design Considerations with Fusible PVC™ · Pit Layout and Design ® 28

Sliplining with Fusible C-900® – Harrisburg, PA Sliplining Client: United Water · 3, 510 linear feet of Fusible C 900® · Host Pipe – 16” cast iron · 12” DR 18 for water line under the Susquehanna River ® 29

Sliplining with Fusible C-905® – El Paso, TX Sliplining Client: Horseshoe Construction for Zaragosa Boulevard · 16, 300 linear feet of Fusible C-905® · Host Pipe – 36” Prestressed Concrete. Lined Cylinder Pipe (PCCP) · 24” DR 25 for water line under Zaragosa Boulevard ® 30

Sliplining 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 ® 31

Pipe Bursting Design Considerations with Fusible PVC™ · 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 ® 32

Pipe Bursting Design Considerations with Fusible PVC™ · 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 ® 33

Ypsilanti, MI Pipe Bursting M-17 (Ecorse Road) Water Main Replacement Project 8”, 12”, and 16” Water Main Pipe Bursts ® 34

Pipe Bursting Ypsilanti, MI - M-17 Water Main Replacement 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 ® 35

Ypsilanti, MI - M-17 Water Main Replacement Project Pipe Bursting · Sample Installation Sequence 1. 2. 4. 3. 5. ® 36

Pipe Bursting Ypsilanti, MI - M-17 Water Main Replacement Project · Potable Water Mains · Michigan DOT and Michigan DEQ approvals required · Pre-chlorinated Pipe Bursting and Horizontal Directional Drilling ® 37

Pipe Bursting Ypsilanti, MI - M-17 Water Main Replacement Project Results · Successfully installed and tested · Minimized public impact – Minimal traffic closure – Minimal commercial impact ® 38

Fusible PVCTM is an efficient and elegant leak-free design in open-trench installation, and also delivers a fully restrained, corrosion free joint Open-Trench/ Direct Bury ® 39

Direct Bury with FPVCTM – Naples, FL Open-Trench/ Direct Bury Client: Collier County, FL · 33, 000 LF of 30”, 24”, 16”, 12”, 8” FPVCTM · Raw water collection system for 12 MGD brackish water RO Facility ® 40

Direct Bury with Fusible C-900® – Sunnyvale, CA Direct Bury/HDD Towne Center Project Potable Water Line · 4, 200 LF Direct Bury · 12” DR 18 Fusible C 900® for new water line ® 41

Selected National A&E Firms Specifying Fusible C-900™/Fusible C -905®/FPVC™ Arcadis Army Corp of Engineers Austin Civil Group Banner Associates Bartlett –West BKF Bolton-Menk Bonestroo Bowen-Collins BP Barber Brelje and Race Brown and Caldwell Carollo Carter and Burgess Conklin, Porter and Holmes CDM CH 2 M Hill Dudek Earth Tech GC Wallace Greeley And Hansen Harris and Associates HDR Interstate Engineering Kennedy Jenks Kimley-Horn Metcalf and Eddy MWH Moore Engineering Nolte Assoc. Parsons Engineering RBF RMC Water Stantec PBS&J Tetra Tech Winzler and Kelly Wilson & Company URS ® 42

Fusible Polyvinylchloride Pipe for Water System Piping · Fusible Polyvinylchloride Pipe Technology requires: – PVC piping that can create integral, fullstrength 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 ® 43

Questions? Richard (Bo) Botteicher, PE (303) 521. 2618 Underground Solutions, Inc. Poway, CA www. undergroundsolutions. com 858 -679 -9551