NeoPoxy 50-Year
Design Life Structures
Using Traditional Materials
David H. Johnson, NeoPoxy Corp.
An engineering guide
for economical
long-life rehabilitation
and protection.
What Are The Problems?
• Hydrogen Sulfide/Sulfuric Acid Attack
• Reduced I&I is lowering flow rates
• Acid generation is increasing
• Deterioration rate is rapidly increasing
• System investment is being lost
What Are The Solutions?
• Cement relining
• Bag liners
• Mechanically locked PVC
• Polyurea & Polyurethane
• PureEpoxy Lining Systems
Why Use A 50-Year
PureEpoxy Structural Design?
34 Foot Structural Liner
– One of 43 Manholes –
Eliminate Failures
Enhances Host Structure
Delivers Long-Term Value
25-Year Proven Design
50-Year Materials Experience
Why Use PureEpoxy Liners?
Monolithic Protection
No annulus
Impervious to H2S
Unaffected by Caustic or Acid
ASTM Design-Compliant
Why Use An ASTM Design?
25-Year Reliability
No Corrosion Failures
No Structural Failures
Conservative, Predictable & Safe
ASTM – An International Standard
ASTM F1216
Wall Thickness Design
Pcr 
1  v (SDR 1) N
ASTM F1216-98 “Partially
Deteriorated” Design Formula
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
ASTM F1216 Wall Thickness vs..
Hydrostatic Load
Partially Deteriorated Design
Wall thickness design increases from 0.25” after the water table is reached
Typical 4’ ID
Manhole Wall Thickness
0.25” (250 mils)
Avg. Water Table
10’ of water= 0.44”
20’ = of water 0.55”
30’ = of water 0.63”
Recognized Corrosion
Resistance Requirements
ASTM F1216-95
10% Sulfuric Acid
5% Nitric Acid
10% Phosphoric Acid
Tap Water
City of Los Angeles*
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
County Sanitation Districts of Los
Angeles Manhole Test
“NeoPoxy NPR-5300 Series in Acid
Vat C97 was inspected on 12/8/03
after 5 months exposure to 10%
H2SO4. So far, there is no color
change or evidence of any problems.
The test will be completed in about 7
more months.”
County Sanitation Districts of Los Angeles County
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 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
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
• Cannot Peel
• Cannot Blister
• Cannot Buckle
Water Load Bearing
Assumption: One square inch
aggregate spacing AND no adhesion to
Fact: The minimum force to pull off
one square inch of embedded
aggregate is 200 psi or 462 feet of
hydrostatic head.
Mechanical Benefits
Impact Tolerant
Aggregate Protects Substrate
Scratches & Nicks Rarely Reach Cement
Aggregate Acts As Corrosion Restrictor
Any Damage Easily Field Repairable
New Pipe Connections
Insert Pipe
1) Cut hole 2) Seal against any incoming water 3) Finish With Epoxy Seal
Additional Pipe Connections
Seal Connection
With Epoxy
1) Cut hole 2) Seal against any incoming water 3) Finish With Epoxy Seal
Preparation & Lining
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
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 most
other methods. Only material costs change, and for
only a small percentage increase you get solid
50-Year Design provides reliable assurance of
Lowest Lifetime Maintenance Cost
Preserves System Investment
Certified Applicator Network
Other Great NeoPoxy
• Potable & Wastewater Pressure Lining Systems
• Heat & Chemical Resistant Epoxy to 300°F
• Environmental Epoxy for Sewer & Storm Drains
Thank you!
Thank YOU!
…for letting us
discuss PureEpoxy
rehabilitation and
(925) 560-1500
Photo Collection of Works
(925) 560-1500