NeoPoxy 50-Year
Design Life Structures
Using Traditional Materials
David H. Johnson, President, NeoPoxy Corp.
An engineering
design guide for
economical
long-life rehabilitation
construction and
protection.
Why Use A 50 Year
PureEpoxy Structural Design?
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34 Foot Structural Liner
– One of 43 Units –
Eliminate Failures
Enhance Host Structure
Receive Long-Term Value
25-Year Proven Design
50-Year Materials Experience
Why Use PureEpoxy?
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Liner After 4 Year
Exposure To Severe H2S
Seamless, Monolithic Protection
Impervious to H2S
Unaffected by Caustic or Acid
ASTM Designs
Why Use An ASTM Design?
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ASTM Is A National Standard
Third Party Testing Requirement
25 Years, CIPP Pipe Design Success
25 Years, No Corrosion Failures
25 Years, No Structural Failures
Reliable, Conservative & Predictable
ASTM Liner Design Inputs
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Flexural Modulus: Short-Term Bending Resistance
Creep Reduction: Long-Term Modulus Reduction
Structure Ovality: Percent Out-of-Round
Enhancement Factor: Tightness of Fit to Host
Poisson’s Ratio: Thinning While In Tensile Pull
Hydrostatic Loads: Known Ground Water Forces
ASTM F1216
Wall Thickness Design
2kEL
1
C
Pcr 

2
3
1  v (SDR 1) N
ASTM F1216-98 “Partially
Deteriorated” Design Formula
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P = groundwater load
k = enhacement factor
EL = long term flexural modulus
v = Poissons ratio
SDR = standard dimensional ratio
C = ovality reduction factor
N = safety factor
Thickness increases with load
Epoxy’s Recognized Bonding Characteristics Provides A Massive Safety Factor
Recognized Corrosion
Resistance Requirements
ASTM F1216-95
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10% Sulfuric Acid
5% Nitric Acid
10% Phosphoric Acid
Gasoline
Tap Water
City of Los Angeles*
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31% Sulfuric Acid**
5% Sodium Hydroxide
5% Ammonium Hydroxide
1% Nitric Acid
1% Sodium Hypochlorite
*121 days in full Immersion – ** 700% LOWER than pH-1
NPR-5300 Epoxy EXCEEDED All Corrosion Performance Requirements
Typical 4’ ID
Manhole Wall Thickness
0.25” (250 mils)
Avg. Water Table
Increasing
Thickness
With
Greater
Load
10’ of water= 0.44”
20’ = of water 0.55”
30’ = of water 0.63”
ASTM F1216 Wall Thickness vs..
Hydrostatic Load
Partially Deteriorated Design
NPR-5300
Wall thickness design increases from 0.25” after the water table is reached
PureEpoxy Liners
100% Solids, No VOC’s
No Solvents
Low Odors
No Shrinkage
Moisture Tolerant
Cures Underwater
Environmentally Friendly
The Solution That Works
DIRECT-TO-AGGREGATE
BONDING
Direct-To-Aggregate Advantages
• Cement is the “weakest link” of
manhole materials. Smooth with
cement minimally in joints &
larger holes.
• Direct-To-Aggregate bonding
is the strongest, most reliable
design. Like sandblasting, it
increases surface area and
increases pull-off strength.
Bonding To Aggregate
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Aggregate Does Not Corrode
Perfect Adhesion Surface
Deeply Anchored
3-D Encapsulated Aggregate
Atomic-Level Chemical Adhesion
Perfect Bond & Seal
Insures that minor cleaning issues do not impact 50 year service life
Design & Benefits
• Bonded Beam Design
• Flexural Modulus Driven
• Adhesion Is Greater Than
Strength of Substrate
Groundwater
• Cannot Peel
• Cannot Blister
• Cannot Buckle
Water Load Bearing
462’
Water
Head
Assumption: One square inch
aggregate spacing AND no adhesion to
mortar.
Force
Fact: The minimum force to pull off
one square inch of embedded
aggregate is 200 psi or 462 feet of
hydrostatic head.
Mechanical Benefits
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Impact Tolerant
Aggregate Protects Substrate
Scratches & Nicks Rarely Reach Cement
Aggregate Acts As Corrosion Restrictor
Any Damage Easily Field Repairable
New Pipe Connections
Break
through
concrete
Insert Pipe
1) Cut hole 2) Seal against any incoming water 3) Finish With Epoxy Seal
Additional Pipe Connections
Seal Connection
With Epoxy
Finished
1) Cut hole 2) Seal against any incoming water 3) Finish With Epoxy Seal
Preparation & Lining
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Preparation & Lining
Water Blast @ 3500-5000 psi
Confirm Surface pH of 6 - 9
Fill & Patch With Cement or Epoxy
Apply 250 Mils Epoxy Liner
SIMPLE and Reliable!
* Direct To Aggregate
How Does Ambient Cure Epoxy
Improve Long-Term Performance?
Thermal coefficient of expansion and
contraction causes heat cured materials to
contract during cool down. Ambient cure
epoxy stays physically “tuned” to the
substrate for maximum adhesion and a
50-year life expectancy.
No annulus for an H2S penetration path.
Chimney Seal Epoxy
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500% Elongation
Traffic Loads OK
Freeze-Thaw OK
Joints & Seams OK
Permanently stops infiltration at rings, seals & moving joints. One step process
Significant Design Points
50-Year Designs are the most economical, reliable
rehabilitation solutions.
Third Party testing combined with an ASTM design
insures that liners perform throughout their 50-year
design life.
Direct To Aggregate bonding is the strongest, best longterm solution for a conservative 50-year design life.
Cost/Benefit Advantages
Mobilization Costs remain the same as for other
methods. Only material costs change, and for only a
small percentage increase you get real “meat on the
bone.”
50-Year Design provides a reliable assurance of
performance.
Lowest Lifetime Maintenance Costs
Other NeoPoxy Products
• Potable Water Structural Lining Systems
• Heat & Chemical Resistant Epoxy to 300°F
• Environmental Epoxy for Sewer & Storm
Toll Free 800-767-3746
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www.NeoPoxy.com
(925) 560-1500