WATER PENETRATION
TEST APPARATUS
ME 493 Final Report – Year 2010
Portland State University
Industry Advisor/Sponsor
Group Members
Academic Advisor
Bryan Hayes
Morrison Hershfield
Andy Park
Luke Defrees
Andrew Williams
Brian Pinkstaff
Dr. David Turcic
Portland State University
1
EXECUTIVE SUMMARY
A small division of Morrison Hershfield, an engineering consulting organization, performs tests
on exterior windows, curtain walls, skylights, and doors for water penetration. It does so
through the use of a spray rack, which is designed to evenly spray water at specified flow rates
(standard ASTM E1105-00) onto each test specimen. Because this standard does not outline
any required design elements other than symmetry, there are potentially unlimited design
possibilities to meet these flow rate requirements. The spray rack that Morrison Hershfield
currently utilizes has a number of design flaws and performance deficiencies that limit
productivity, and produce questionable results.
This capstone project involves addressing these deficiencies, by designing, prototyping, and
testing an original, fully-operational spray rack that meets these standards, and satisfies the
constraints set forth by Morrison Hershfield. At the start of this project, these constraints were
defined in a PDS document, along with a timeline outlining the goals for completing different
stages of the project. This report evaluates the overall success of the project by examining
whether each of the constraints specified in the PDS were met.
2
TABLE OF CONTENTS
Executive Summary…………....………………………………………………………………………...
2
Introduction and Background.……..………………………………………………………..……...
4
Mission Statement..............................................................................................
5
Main Design Requirements…………………………………………………………………………….
5-8
Final Design….…………….…………………………………………………………………………..……..
8-11
Evaluation of Design.……….…………………………………………………………………….….…..
12-15
Conclusion…….…………………………………………………………………………………….…….…..
15
Appendices.........................................................................................................
16
A. Assembly Components...............................................................................................
B. Justification of Final Design........................................................................................
C. Operation Manuals………………………………………………………………………………………………..
D. Product Data Specification Table...............................................................................
E. House of Quality……….................................................................................................
F. Part Drawings……………….............................................................................................
G. Bill of Materials.…………..............................................................................................
H. ASTM E 1105-00 Standard..........................................................................................
17-21
22-34
35-36
37-38
39
40-48
49-52
53-57
3
INTRODUCTION AND BACKGROUND
the catch box in front of the nozzles and
simulating a spray test for a long enough
Morrison Hershfield’s building science
period of time to gather a measurable
consultants test the resistance of installed
amount of water. The flow acquired from
products such as windows and doors to
each corner must be within the range stated
water penetration. The tests are performed
in the ASTM standard.
using a spray rack, which is a labyrinth of
piping containing strategically placed nozzles
that project water uniformly against a test
specimen. An example of a spray rack can be
seen in Figure 1. The amount of water
applied to a test specimen must meet the
flow requirements outlined in the ASTM E1105 standard, which details the constraints
for successful water penetration tests.
Figure 2. Catch box currently used by Morrison hershfield to
calibrate their spray rack.
Upon completion of a test, the installed test
specimen is thoroughly inspected for water
leakage. If any leakage is discovered,
appropriate action is taken to determine the
party at fault. Although the current spray
rack apparatus used by Morrison Hershfield
is not calibrated properly, it is the only
Figure 1. Typical spray rack device used in water penetration tests.
system available for their building science
consultants. This is one of the primary
In order to meet the flow requirements, the
spray rack must be calibrated every six
months. Calibration is done using a catch
box, as seen in Figure 2. Each of the four
reasons our group has been asked to
improve upon their current device. Other
significant design considerations that have
been addressed by the customer include:
corners of the rack are calibrated by placing
4
modularity, material integrity, and portability
of the rack itself. These product conditions
and performance criterion have been
examined and presented in the team’s
Product Design Specification table in
Appendix D.
• Improve portability and usability of
previous design
• Ensure safety and structural integrity of
design
• Nice aesthetics and professional
appearance
• Is completed within Morrison Hershfield’s
MISSION STATEMENT
budget
The Water Penetration Test Apparatus Team
will design and prototype a spray rack system
ASTM E 1105-00 Calibration Standards
to exceed the performance and usability of
Meeting the calibration requirements
Morrison Hershfield’s current testing device.
verifies that the water penetration testing
In addition, an easy to use catch box will be
device performs properly. The key elements
designed and fabricated in order to meet all
of functionality include a uniform spray
of the calibration and testing standards
pattern and meeting a target spray rate. As
outlined in the ASTM E 1105-00 document.
stated in the standard, the water spray
Finally, this project will be completed on
system shall deliver water uniformly against
time, meeting appropriate deadlines, and
the exterior surface of the test specimen at
within the budget requirements outlined by
a minimum rate of 5.0 US gal/ft2-hr. The
Morrison Hershfield.
acceptable tolerance for the device ranges
from 4-10 US gal/ft2-hr.
MAIN DESIGN REQUIREMENTS
Improved Portability and Usability
In order for this project to be considered
The ease of use of the water penetration
successful, it must meet the following
testing device relies upon required
requirements:
manpower, setup time, and transportation.
The device should be assembled,
• Meet flow rate requirements of ASTM
standard E 1105-00
transported, and operated by one person
unless it is being used in suspension which
would require two people. The assembly or
5
disassembly of the spray device should take a
consistent in appearance throughout the
maximum of 5 minutes. Most of the parts
rack.
need to be stock and easily replaceable in
case they break or malfunction. Finally, it is
important that the device is able to be
transported via a compact passenger car,
eliminating the need for a truck/utility
Top-Level Alternative Conceptual Solutions
After brainstorming possible design ideas,
the team evaluated three final design
solutions. A circular rack, flexible tubing
rack, and a square modular rack were
vehicle.
compared to the current Morrison Hershfield
Structural Integrity
model in the scoring matrix in Table 1 below.
The structural integrity of the water
The square modular rack accumulated the
penetration testing device maintains that it
highest score.
will withstand the stresses acting on it during
Table 1: Decision matrix for 3 possible design solutions.
Morrison Hershfield
Square Modular Rack
Flexible Tubing Rack
Circular Rack
operation. The spray device must be
Portability
3
4
5
5
operation. The device also needs to
Ease of Use
3
4
3
4
withstand the rough handling and abuse of a
Maintenance
2
4
2
4
Durability
2
4
2
2
Calibration
1
5
3
3
Adjustable Spray Range
3
4
3
3
Safety Features
3
4
4
4
ASTM E1105
3
5
3
4
Manufacturing
4
5
2
2
Cost
4
4
4
2
Total
28
43
31
33
43 86
% of Possible Score
1 = low, 5 = high
62
66
structurally sound when standing on the
ground or in suspension. This ensures the
safety of the users and other individuals
within the proximity of the device during
construction environment while maintaining
functionality. Because the device will be
regularly exposed to water, all the device
parts need to be corrosion resistant.
Aesthetics
The water penetration testing device should
PDS Criteria
have a neat and professional appearance.
Other key details include hardware that is
6
Circular Test Apparatus
The circular test apparatus, shown in Figure 3
below, has the following advantages:
• Easily disassembled: the piping can be
unthreaded from the center hub to be
broken down into an easily carried bundle.
• For a 5 x 5 ft specimen, this design will
meet the uniformity specification.
• Extra piping can be threaded to the ends of
each pipe to test larger specimens.
• Because this device can be completely
disassembled, parts may get misplaced.
• The lack of structure on the outer pipes
could result in severe damage if dropped or
impacted.
Flexible Tubing Apparatus
The flexible tubing design, show in Figure 4
below, has the following advantages:
• Assembly affords flexibility in transport.
• Cost of materials is very low.
• Overall weight is very low.
Figure 3: Circular Apparatus Assembly
Figure 4: Flexible Tubing Assembly
The design has the following disadvantages:
The following limitations of this design
• Manufacturing is expensive.
include:
• Onsite assembly would be difficult.
• If testing large specimens (up to 10 x 10 ft)
• Calibration setup would be inconsistent.
the extra piping will not meet the uniform
spray grid requirement. There will be
Square Rack
excessively large gaps between the pipe
The square rack, shown in Figure 5 below,
ends.
includes the following advantages:
• This device would be harder to fabricate
than a rectangular spray rack.
• Easily adjustable to accommodate a variety
of different sized test specimens.
7
• Easy to manufacture.
telescoping stand were selected to be
• Horizontal water supply pipe fit with valves
manufactured at the PSU machine shop with
capable of creating consistent pressure
Aluminum T6061-T6.
throughout the rack.
The primary material is ¾ in. copper tubing
• With the aid of quick release copper
that is brazed together and painted Morrison
couplings, rack can be broken down and
Hershfield colors. The overall structure
disassembled for portability.
meets industrial grade requirements for
stress and reliability. This design allows
simple monitoring and adjustment of flow
rates if the rack were to fall out of
calibration. Portability is also maximized
with quick release copper couplings, easily
disassembled side supports, and medium
length horizontal pipes.
Figure 5: Square rack assembly
The design had the following disadvantages:
• Heavier than other designs.
• Moderately high cost to fabricate.
FINAL DESIGN
Overview
The overall water penetration test system
Final Design
constructed for Morrison Hershfield consists
Our final design incorporates the advantages
of four main assemblies. These items include
from each design. The final design is simple,
the spray rack system, spray rack stand,
cost effective, and calibrated. The horizontal
calibration stand, and calibration box. The
design eliminates the need for multiple
following sections describe each of these
valves and pressure gages. The design can be
parts in detail. Specific components
semi-permanently set, with no additional
important to the functionality of the main
need for adjusting valves and regulating flow
assemblies can be found in Appendix A.
after the initial calibration. The hanging
mounts, vertical supports, wall spacers, and
8
Spray Rack
car. To give the spray rack form and rigidity,
The spray rack system shown in Figure 6 was
aluminum vertical supports were
designed to meet the requirements
incorporated into the design. The supports
presented in the PDS document. In order to
also restrict rotation of the horizontal spray
achieve equal flow rates from the top to
pipes at the quick release coupling
bottom sections of the spray rack, a single
connections.
vertical supply pipe was designed with two
flow regulating valves placed between the
three horizontal spray pipes. Appropriate
valves were selected such that the user can
throttle the system to obtain consistent flow
rates at all elevations then remove the valve
handle. This minimizes the risk of accidental
throttling while the system is on a job site,
and hence un-calibrating the system.
Figure 6: Front view of the final spray rack system.
At the inlet of the vertical supply pipe a
pressure gauge is placed following the inlet
throttling valve. This characteristic was
designed to meet ASTM standards. When
water is introduced to the system, the user
can adjust the inlet throttling valve to obtain
the appropriate calibration pressure. The
horizontal spray pipes are connected to the
vertical supply pipe by quick release copper
couplings. Selection of the couplings was
made to allow disassembly of the entire
spray rack system. When disassembled, the
rack can be bundled together and
transported to a job site in a small passenger
Small orifice (0.05 in.), 120 deg full cone
spray nozzles were selected to meet the
necessary flow rates outlined in the ASTM
standard. Appendix B shows the necessary
calculations used in nozzle selection. Placing
the nozzles 2 ft. apart on the horizontal pipes
and 2.25 ft. vertically, the spray pattern
achieves approximately 30% of overlap
between all adjacent nozzles when the spray
rack is spaced 12 in. away from a test
specimen. Significant spray overlap is
necessary to ensure wetting of all parts of a
test specimen.
9
Telescoping window spacers were designed
two sandwiched plates that secure it in the
to allow proper spacing between the spray
same plane as the telescoping tubing. Eye
rack and a test sample. The telescoping
bolts allow for the use of industrial strength
tubing allows for spacing between 10 and 18
carabiners to make the connection between
inches. By spacing the rack 18 in. away from
the spray rack stand and the hanging mounts
a sample, the water coverage area can be
of the spray rack system. The stand can also
increased from 33 - 53 ft2 when compared to
be used during calibration to hold the rack
12 in. of spacing. Increasing the distance
securely on the ground. Because the stand
from the rack to the specimen requires an
will be used for these multiple elevations, a
increase in system pressure in order to
pivoting system was designed at the base to
maintain proper water flow rate
allow shallow angles of the stand during
requirements. Hanging mounts were
calibration and large angles when the stand is
designed for easy suspension of the spray
used to elevate the spray rack. Installed on
rack with either ropes or the spray rack
the bottom of the base plate is a thick rubber
stand.
slab to ensure large frictional forces to hold
the stand in place on surfaces like cement or
Spray Rack Stand
concrete.
The installed products that Morrison
Hershfield test range from ground level to
multi-story, high rise buildings. Specimens
on the second floor and higher must be
tested by suspending the rack from ropes.
Products at ground level and on the first floor
of a building can be tested using the spray
rack stand illustrated in Figure 7. In order to
reach heights of up to 9 ft. above the ground,
thick walled aluminum telescoping tubing
Figure 7. Spray rack stand assembly.
Calibration Stand
was selected as the main structure of the
During calibration of the spray rack system,
stand. The horizontal tube is held in place by
the calibration box and graduated cylinders
10
must be placed on a stand to reach the
required locations detailed in the ASTM
standard. The stand designed in Figure 8
accomplishes this task by incorporating a
vertical pole held in place by a tripod base.
All materials of the stand were chosen to be
aluminum for corrosion resistance and
weight reduction.
The bottom plates of the stand are 0.25 in.
thick aluminum that are designed so the
vertical tube can protrude through the top
plate, and rest on the bottom plate. An
acrylic block is situated where the tube rests
on the bottom plate and forms a tight fit on
the inside of the vertical tube for further
restriction of sideways movement. This
configuration allows the vertical tube to be
removed from the base for compact storage.
The total height of the stand is 6 ft, which
exceeds the maximum height of the spray
rack system, allowing all possible locations of
the rack to be calibrated.
Figure 8. Calibration stand assembly.
Calibration Box
The catch box in Figure 9 is used to gather
the impinging spray from the rack during
calibration, and was designed according to
the ASTM standard. It is 2 x 2 ft. and
separated into four equal sections. The walls
of the calibration box are 4 in. wide to ensure
that all of the spray water is captured and
accumulates within the box. A hole is drilled
in the bottom corner of each of the four box
sections. Micro tubing can be installed in the
holes through the back of the calibration box
to displace the water from the collecting
areas to the graduated measuring containers.
To hang the rack on the calibration stand, an
I-plate configuration was designed. Two
small 0.25 in. thick plates are bolted 12 in.
apart on the back of the box. When the Iplate is bolted to the two spacing plates, the
box can be fastened to the calibration stand
11
by two hose clamps. The full assembly can
acceptable flow rates must be between 0.25
be found in Appendix A.
– 0.63 liters/min-ft2.
Figure 9. Final manufactured calibration box.
Figure 10: Locations for testing flow rates of the spray rack.
Each square represents 1 square foot, and each grouping of
EVALUATION OF DESIGN
4 squares represents how samples were taken.
After the final design was approved by
After testing the rack at various internal
members of Morrison Hershfield, a prototype
pressures, the minimum pressure required at
of the final design was fabricated, and
a 12 inch rack-wall separation for acceptable
various aspects of the design were evaluated
flow rates across the entire spray surface was
according to the product design
found to be 25 psi. At 25 psi, the range of
specifications.
flow rates were 0.25-0.49 liters/min-ft2,
meeting ASTM requirements at all four
Flow Rates
locations. If the internal pressure of the
The ASTM E 1105-00 standard requires that
system were to fall below 25 psi, parts of the
the spray rack be tested for flow rates at four
spray surface may not receive acceptable
specific locations at the theoretical surface:
flow rates. At 20 psi, the flow rates at the
both the upper corners, and at locations
top corners fell below 0.25 liters/min-ft2, but
along the horizontal center, one quarter the
the center test areas did not. This is largely
length of the total width from each side.
due to the fact that there is minimal spray
Figure 10 shows the four locations below.
With 1 ft2 sample areas, the range of
12
nozzle overlap at the outermost sample
areas.
At an 18 inch rack-surface separation, the
spray rack effectively covered 61% more
surface area, but the required internal
pressure of the system rose to 30 psi. When
the pressure of this system fell below 30 psi,
it behaved almost identically to that of the 12
inch rack-wall separation system.
Portability
The portability of the new spray rack system
has fully satisfied the requirements of the
Figure 11: The spray rack disassembled and bundled with
Velcro straps.
PDS. The rack can be assembled/
disassembled on site by one person in
The spray rack and stand were tested and
approximately 5 minutes, which minimizes
easily fit into a compact sedan (Nissan 200SX)
the additional time needed to improve
by one person. Rubber caps were also
portability.
attached to the ends of each member, shown
Disassembled and bundled with Velcro straps
in Figure 12, so that forces of impact from
shown in Figure 11, the rack’s dimensions are
transportation and industrial handling will be
6 ft. long, with its largest diameter equal to
more effectively absorbed.
about 9 inches. The spray rack stand, used
for mounting at ground level applications, is
Maintenance
a 6.5 ft long, which intersects perpendicularly
Although the spray rack has not required any
at one end with a 3 ft section of tube.
maintenance after the fabrication was
completed, the team does not foresee many
instances where potential problems could
not be easily maintained and serviced in the
field or at the Morrison Hershfield facility.
13
Copper was chosen as the piping material
Setup/Operation
with soldered joints. If a section of piping,
The setup and operation constraints of the
valve, or pressure gage were to be
PDS were satisfied, maintaining or improving
irreparably damaged, the affected area can
upon the current spray rack used by
be cut out if needed, and replaced with parts
Morrison Hershfield. As mentioned
commonly found at most hardware stores. If
previously, assembling the rack can be
leaks occur, the joints can be heated and re-
routinely performed in about 5 minutes by
soldered.
one worker. The ground level stand is a
Brass nozzles and bushings, shown in Figure
single telescoping tube, which can be
12, were chosen with simple designs to
controlled by one person. Once assembled,
minimize corrosion, to be easily cleaned of
the rack (without water) weighs 24.3 lbs,
clogs, and easily replaced. These parts were
which is far below the PDS constraint of
purchased online at the popular website
50lbs, allowing one person, instead of two
McMaster-Carr, where in the event a nozzle
for the current spray rack, to setup and
or bushing becomes damaged, the part can
mount the spray rack at ground level
be replaced within a couple of business days
applications.
at minimum cost.
The total setup of the rack or mounting of
the rack to the installation at ground level
takes no more than 15 minutes, which
satisfies the PDS requirement. The team was
unable to test the suspension mounting time,
due to limited resources.
Although it is conceivable that the spray rack
be setup and mounted onto roof-suspended
Figure 12: Rubber caps and brass nozzles and bushings were used in
the final design, which require little maintenance, and are easily
replaceable.
applications by a single worker, the new
design was intended to be operated by two
workers; which is also required for Morrison
Hershfield’s current spray rack. This is due to
the increased degree and quantity of risk
14
inherent to suspending a spray device of this
only the internal pressure of the device at
size from a large building. Two workers can
steady state needs to be monitored. The
ensure more stability and accuracy in
project was also completed in the timeline
suspending this device, and can monitor each
specified, meeting acceptable deadlines, and
other as well to ensure there are no crucial
under budget by $300.
oversights that may result in injury or even
Brian Hayes of Morrison Hershfield has
death of people below.
viewed the prototype and was pleased with
The simplicity of operating the rack is
the final design. He commented that all of
maintained, where only the internal pressure
the major assemblies were more functional
of the system needs to be monitored. The
and appeared more user friendly than their
coverage area and expandability however are
current device. By meeting or exceeding the
improved. The current design used by the
requirements outlined in the PDS, the
project sponsor has a relatively small, fixed
customer, and the PSU capstone curriculum,
coverage area. With the new design, the
the design and prototyping of our water
spray rack has a larger coverage area, which
penetration testing apparatus was a success.
can also be expanded if necessary.
CONCLUSION
The team has designed, fabricated, and
tested a water penetration testing device
that meets or exceeds the requirements set
forth in the product design specifications.
Most importantly, our testing showed that
flow rates of the spray rack at an internal
pressure of 25 psi satisfy the ASTM
requirements. The rack is more easily
transported and covers a larger surface area
than the customer’s current apparatus.
Operation simplicity is maintained, where
15
appendices
16
APPENDIX A: ASSEMBLY COMPONENTS
The following components and parts were used in the main assemblies of the entire spray rack
and calibration system.
Name: Spray Rack System
Main Assembly: Spray Rack
System
Description: The spray rack
system is used to uniformly
spray water on installed
exterior products.
Name: Nozzle Spray Pattern
Main Assembly: Spray Rack
System
Description: Spacing the spray
rack 12 in. from the test
specimen results in the
illustrated water spray pattern.
Nozzle spacing was selected to
achieve approximately 30
percent of spray overlap for
proper uniformity of spray onto
the specimen.
Name: Quick Release Copper
Coupling
Main Assembly: Spray Rack
System
Description: The couplings were
selected to connect the
horizontal spray pipes to the
vertical supply pipe. Quick
release couplings allow for
disassembly of the entire spray
rack system for ease of
transportation.
17
Name: Disassembled Spray Rack
System
Main Assembly: Spray Rack
System
Description: When completely
disassembled, the spray rack
system can be bound by Velcro
straps and transported in a
small passenger car.
Name: Telescoping Window
Spacers
Main Assembly: Spray Rack
System
Description: The spray rack
must be spaced 12 in. away
from the test specimen to
achieve the cover pattern
presented above. Telescoping
winder spacers allow the user
to achieve this distance, and
increase the distance to expand
the spray coverage area.
Name: Hanging Mounts
Main Assembly: Spray Rack
System
Description: In order to suspend
the spray rack by ropes or the
spray rack stand, the hanging
mounts must be used to relieve
stress on the copper piping. The
two part design allows for
adjustment of the mount in
horizontal and rotational
directions by loosening the
bolts and positioning in the
correct orientation.
18
Name: Vertical Supports
Main Assembly: Spray Rack
System
Description: To give the spray
rack rigidity, the vertical
supports can be installed onto
the horizontal spray pipes to
eliminate rotation of the pipes
at the quick release coupling
connections.
Name: 0.05 in., 120˚ Full Cone
Spray Nozzles
Main Assembly: Spray Rack
System
Description: The nozzles
selected produce a flow rate of
0.4 GPM at 30 psi.
Name: Pivoting Stand Base
Main Assembly: Spray Rack
Stand
Description: To achieve a range
of angles necessary for the
spray rack stand, the pivoting
base was designed to allow the
user to easily position the stand
and rack where ever it needs to
be placed.
19
Name: Calibration Stand
Assembly
Main Assembly: Calibration
Stand
Description: Stand used to hold
the calibration box and
container rack at heights
governed by the ASTM
standard.
Name: Calibration Stand Base
Main Assembly: Calibration
Stand
Description: To reduce sideways
motion of the vertical tube, the
acrylic block forms a tight fit
against the inside of the square
tubing. This allows eliminates
the need for permanent fixing,
and permits easy storage as two
separate parts.
Name: Container Rack
Main Assembly: Calibration
Stand
Description: The container rack
is used to hold the graduated
containers by sliding the two
horizontal square tubes through
the handles of the containers.
Name: Calibration Box
Main Assembly: Calibration Box
Description: 2 ft. x 2 ft. box
divided into four equal sections
used to collect water during
calibration.
20
Name: Calibration Box I-Plate
Main Assembly: Calibration Box
Description: By spacing the Iplate 0.25 in. from the back of
the calibration box, two hose
clamps can sufficiently hold the
box to the calibration stand.
Name: Calibration Box Hose
System
Main Assembly: Calibration Box
Description: To get the water
from the calibration box to the
graduated containers, the hose
system consists of microsprinkler tubing and spigots.
21
APPENDIX B: JUSTIFICATION OF FINAL DESIGN
To validate the usability and integrity of our final design, the following tests, calculations, and
analyses were completed.
Spray Rack Deflection during a Water Penetration Test
Given: The water penetration testing device consists of a grid of nozzles. The nozzles are
placed in specific locations in order to meet the requirements of flow rate and coverage area
stated in the ASTM E 1105 standard. The rack is composed of one vertical ¾ in. copper pipe
connected to three horizontal ¾ in. copper pipes that house the nozzles. The copper pipe’s
outer radius is 0.4375 in. with a thickness of 0.065 in. In addition to the piping there are two
4.5 ft. aluminum members supporting each side of the rack with cross sectional dimensions of
0.25 x 1.5 inch. The rack is suspended from two mounts symmetrically located on the top
horizontal member of the rack, each spaced 1.5 ft. from the vertical centerline. The copper
pipes, when filled with water carry a distributed force of 0.11 lb/in, while the aluminum support
members carry a distributed force of 0.0375 lb/in.
Suspension Location
Copper
Pipe
Nozzle
Vertical
Support
22
Find: Given the loads impressed upon the spray rack, is the deformation in the spray rack
substantial enough to change the nozzle placement and alter the geometry of the rack enough
to undo the calibration specs?
Solution: A simplified model using ABAQUS software was used in order to solve the problem
with finite element methods. Rack was sketched and profiles implemented based on given
information about cross sections of the pipe and aluminum members.
The boundary conditions can be seen in the image above. There was no translation at the
hanging points of the rack. Displacement was allowed at every other location of the model. The
copper pipes that channel the water had a downward load of 0.11 lb/in and the aluminum
members had applied forces of 0.0375 lb/in.
23
Results: The image above shows the solution to the ABAQUS spray rack model.
The displacement of the rack varies from 0.003 to 0.03 inch. The greatest displacement occurs
where the suspension is made. The displacement at these points is approximately 0.03 inch
which is negligible compared to the overall dimensions of the spray rack. This small amount of
deflection will have no affect on the functionality of the rack during a water penetration test.
Shear Strength of Copper Tubing
Given: During a water penetration test, the rack is suspended by the hanging mounts. The
entire weight of the rack is 35 lbs when water is added to the system. The 0.5 inch thick
hanging mounts are attached to ¾ inch copper pipe which has shear strength of 42 MPa (6100
psi).
Find: Will the copper piping fail in shear due to the weight of the entire rack during a water
penetration test?
Solution: The hanging mounts are located symmetrically along the top horizontal spray pipe,
and split the weight of the rack during a test. When suspended, therefore, the force applied to
the pipe at the location of each hanging mount is half of the rack’s weight.
Wt = 35 lbs
FA = FB = Wt/2 = 17.5 lbs
The equation to calculate shear stress is:
τ = F/A
24
The necessary information to calculate the area of the applied shear stress is the width of each
mount and the diameter of the copper pipe:
Hanging mount width = W = 0.5 in.
Copper pipe diameter = D = 0.875 in.
Area of applied force = W x D = 0.5 x 0.875 = 0.4375 in 2
Shear stress can then be calculated by employing the shear stress equation from above:
τ = 17.5 lb / 0.4375 in2 = 40 psi
Results: The shear stress developed where the hanging mounts are fastened to the copper
piping is 40 psi. The shear strength of the copper is 6100 psi which is much higher than the
stress impinging on the pipe at the hanging mounts. Shear stress developed by the hanging
mounts during a test, therefore, will not exceed the rack’s material constraints.
Stress Analysis of Hanging Mounts
Given: A ¾ inch diameter copper pipe spray rack with a weight of 35 lbs (weight includes
water, hardware, vertical supports, and valves). The pipe has a thickness of 0.065 inch. Mounts
are fastened on the top pipe of the rack, spaced 3 ft. apart uniformly from the vertical line of
symmetry. The material of the hanging mounts is T6061-T6 aluminum with a thickness of 0.5
inch. The dimensions for the profile of the mounts are listed below.
Find: Determine the Von Mises stress in the hanging mount, and determine the factor of safety.
Solution: C3D8I: An 8-node linear brick, incompatible mode elements.
Using a finite element software package such as ABAQUS, the analysis can be performed to
determine the static stress on the hanging mount. Taking advantage of symmetry, the
computation time was reduced and it allows for a more refined mesh for the same number of
elements.
25
Loading ConditionsTotal Rack Weight / 2 mounts = weight per mount = 35 lbf/2 = 17.5 lbf
Surface area of inside surface of hanging mount where the carabiner will be hooked =
0.07 in2
Pressure load 17.5 lbf / 0.07 in2 = 250 psi
Boundary Conditions:

Fixed Support (clamped section of mount to copper) no x, y, z translation or
rotation.

Symmetry about y plane (y-displacement = 0, rotations about x and z = 0) (1/2
thickness = 0.25 inch).

Symmetry about the x plane, half width (x-displacement = 0, rotations about y
and z = 0).
The model was setup with a hex sweep mesh of 2048 3D stress shell elements. The area of
maximum stress is just above the fillet on the left and right side of the triangle cutout. The Von
Mises stress and displacement magnitude are as follows:
26
Results: For the static loading analysis there is a large factor of safety, because the mounts
were designed to withstand an impact load. The ABAQUS stress analysis shows a maximum
Von Mises stress magnitude of 0.45 ksi with a factor of safety of 29 and a maximum
displacement magnitude of 4.489e-5 inches. These mounts are designed to be able to
withstand the stresses applied by the total weight of the rack, water, hardware, and vertical
supporting mounts under a static load.
Spray Nozzle Selection
Given: The spray rack system uses full cone nozzles that spray at 120˚. The nozzle supplier
offers many different sizes of orifice for this type of nozzle which operate efficiently at different
pressures. The nozzles of the spray rack are positioned along the grid as shown in the
illustration below. The spray system impinges onto a surface 12 inches away from the nozzles.
27
The surface needs to be sprayed at a flow rate of at least 5 gal/hr-ft2 (0.0833 gal/min-ft2), as
outlined in the ASTM standard. The diameter of the spray coverage at the test specimen is
equal to 3.46 feet. The figure is to scale. The box represents 90% of the actual spray area
covered by the nozzles.
Find: What is the minimum flow rate required out of each nozzle in order to meet the flow
requirement impinged on the box shown in the figure. Use this information to choose the most
appropriate spray nozzle selection for the rack.
Solution: Area of spray coverage = A = length*height = 6.75*6 = 40.5 ft2.
Total flow rate for this coverage area = 5 gal/hr-ft2 * A = 202.5 gal/hr (3.375 gal/min)
With the total flow rate necessary to meet the constraints in the ASTM standard, the amount of
water exiting each nozzle can be calculated by:
Total flow Rate / # of nozzles
(3.375 gal/min)/12 nozzles = 0.281 gal/min-nozzle
Because the area of the box is smaller than area covered by nozzles, the flow rate must be
adjusted so that it sprays the entire spray area at the minimum required rate; assume a 90 %
adjustment factor.
Required flow rate from each nozzle at 25 psi = (Flow rate/nozzle) / 0.90
(0.281 gal/min)/0.90 = 0.313gal/min.
28
Conclusion: An acceptable flow rate for each nozzle is approximately 0.31 gal/min. Based on
the supplier’s selection of nozzles, for an inlet pressure of 25 psi and a required flow rate of
0.32 gal/min, the recommended nozzles are 1/8 inch pipe size with an orifice diameter of 0.05
inch. These nozzles can produce 0.3 gal/min at 20 psi and 0.5 gal/min at 40 psi, making them
the most appropriate nozzles selection.
Horizontal Pressure Differences in the Spray Rack
Given: Uniformity of spray rates is required along the horizontal spray pipes of the rack as
detailed in the ASTM standard. Junction and friction pressure losses that occur within the
piping will affect the spray rates as the flow moves further from the inlet water supply. A test
rack was made of a 6 ft. long, ¾ inch PVC pipe with drilled orifices simulating nozzle spray
diameters. The inlet water pressure was 40 psi and produced a flow rate of 3.2 GPM.
Find: Determine whether or not there is sufficient evidence of a difference in flow rates exiting
the orifices along the horizontal spray pipe.
Results: To test the differences in flow rates along the horizontal pipe, an experiment was
devised to complete the task. Four equally spaced small orifices were drilled into the pipe 9
inches apart on each side of the horizontal center. A graduated container was used to gather
water for 1 minute from each orifice. Two different trials of data were collected for each
orifice.
29
After sufficient data was gathered for the smallest orifice size, the hole diameters were
increased. The three orifice diameters tested were: 0.128 in., 0.161in., and 0.209 in. The
results of this data are presented in the ANOVA test below.
The following hypothesis and null hypothesis were developed to test the effects of pressure
differences in the horizontal pipe:
Ho = The flow rates from each hole are equal as the distance from the horizontal center
is increased.
HA = Flow rates are significantly different as the distance from the center is increased.
α = 0.05
ANOVA: flowrateout versus holediameter, hole, trial
Factor
holediameter
hole
trial
Type
fixed
fixed
fixed
Levels
3
4
2
Values
0.128, 0.161, 0.209
A, B, C, D
1, 2
Analysis of Variance for flowrateout
Source
holediameter
hole
trial
holediameter*hole
holediameter*trial
hole*trial
Error
Total
S = 0.00395360
DF
2
3
1
6
2
3
6
23
SS
0.00018567
0.00005326
0.00001603
0.00023994
0.00000744
0.00001842
0.00009379
0.00061455
R-Sq = 84.74%
MS
0.00009283
0.00001775
0.00001603
0.00003999
0.00000372
0.00000614
0.00001563
F
5.94
1.14
1.03
2.56
0.24
0.39
P
0.038
0.407
0.350
0.139
0.795
0.763
R-Sq(adj) = 41.50%
Boxplot of Flow Rate (gpm)
Flow Rate (gpm)
0.4
0.3
0.2
0.1
0.0
Hole Location
Hole Diameter (in)
A
B
C
0.128
D
A
B
C
0.161
D
A
B
C
0.209
D
30
Conclusion: Multiple factors were tested, the most applicable being the hole vs. flow rate. Our
hypothesis test was designed with a level of significance of 95%. The P-value for the tested
factor was 0.407 which is much greater than 0.05. This result was similar for the other two
orifice diameters tested. With this high P-value, we fail to reject the null hypothesis and it can
be concluded that the difference in flow rates is insignificant as the orifice distance increases
along the horizontal pipe. Through the results of this test, it was determined that there is no
need for flow regulation along the horizontal spray pipes.
Vertical Pressure Differences on the Spray Rack
Given: A full sized test-spray rack was constructed out of
PVC pipes with holes drilled in the same locations as the
final design. Each of the orifices were drilled with a 0.209
in. diameter. Water was introduced into the system from a
standard garden hose tap with 40 psi of water pressure
available. The configuration and dimensions of the testspray rack can be seen in the illustration. When water was
spraying from each of the orifices, the spray streams
reached the locations detailed in the figure.
Find: For the differences in elevation between the top, middle, and bottom horizontal spray
pipes, find the internal pressure of the water behind each spray orifice.
Solution:
Variables used in the following calculations:
t = time (s) h = vertical height (m) g = gravitational constant
v = velocity (m/sec)
d = distance (m)
The time required for the water to fall the vertical distance is equal to:
t = ((2*h)/g)1/2
t = ((2*0.61 m)/9.81 m/sec2)1/2 = 0.35 sec
The velocity at the orifice exit is equal to
31
V2 = d/t
V2 = 2.49m/0.35 sec = 7.06 m/sec
Using the Bernoulli equation, we can evaluate the pressure at points just before the orifice.
𝑃1
𝑉12
𝑃2
𝑉22
𝑧1 +
+
= 𝑧2 +
+
𝜌𝑔 2𝑔
𝜌𝑔 2𝑔
Assumptions that can be made:
z 1 = z 2,
V1 = 0,
P2 = 0
With these assumptions the Bernoulli equation reduces to:
𝑉22 𝜌
𝑃1 =
2
To calculate the pressure before the orifice at the lowest horizontal spray pipe (elevation = 2 ft.)
the following example calculation is made:
P1 = ρv22/2
P1 = [(1000 kg/m3)*(7.06 m/sec)2]/2 = 24943.81 pascals
By converting pascals to psi we get:
24943.81 pascals*0.00014503774 psi/pascal = 3.62 psi
The equation used above to calculate the pressure just before exiting the orifices at an
elevation of 2 ft was used to calculate the pressures for elevations of 4 and 6 ft. These results
can be found in the table below.
h = starting
height (ft)
6
4
2
x=
t = time to
distance
velocity
hit ground
traveled
(m/s)
(s)
(m)
1.83
2.3
0.61
3.77
1.22
2.45
0.50
4.91
0.61
2.49
0.35
7.06
h = starting
height (m)
pressure in
pipe at orifice
(pascals)
Pressure in
pipe at
orifice (psi)
7094.12
12074.42
24943.81
1.03
1.75
3.62
Results: The pressure behind the orifices at the three different elevations are as follows: at a
height of 6 ft. the pressure was 1.03 psi, at a height of 4 ft. the pressure increased to 1.75 psi,
and at 2 ft. above the ground the pressure was 3.62 psi. The pressure in the bottom horizontal
spray pipe is approximately 3 times greater than the top spray pipe. This amount of
inconsistency requires throttling at the different elevations of the spray rack to achieve
uniformity of pressures within the system. To solve this problem, the final design uses two
32
throttling valves along the vertical supply pipe in order to eliminate pressure differences among
elevation changes.
Calibration Test Data
Required: The ASTM E1105-00 standard requires that three specific areas of the spray rack are
calibrated to ensure proper water coverage. These areas include both upper corners and the
quarter point of the horizontal center line. Calibration entails that the water gathered from the
calibration box exceeds 1.26 L/min total for the four areas, and is between 0.25 to 0.63 L/min
for any one section of the calibration box.
Procedure: To accurately calibrate the spray rack, the calibration box was positioned to the
correct location and spaced 12 in. from the rack. Water was applied to the system via a
standard garden hose tap. The flow was throttled at the inlet to three different pressures: 20,
25 and 30 psi. When water began filling the graduated containers, a stop watch was started.
The spray rack was turned off after 2 minutes of water impinging upon the calibration box. The
water collected in each graduated container was recorded and divided by 2 to obtain the
appropriate L/min measurement. After testing each of the three inlet pressures at all of the
three calibration locations the data was organized and can be found below.
Results:
For an inlet pressure of 20 psi the lowest flow rate was in the upper right corner of the rack and
was 0.15 L/min, which is below the requirements of the standard. This inlet pressure does not
meet the minimum flow rate of the total four calibration box areas (1.26 L/min) either. The
spray rack does not meet ASTM standards at an inlet pressure of 20 psi, when spaced 12 in.
away from a test specimen.
Calibration data for an inlet pressure of 20 psi.
Captured Water in (L/min)
Calibration Box Section
Calibration
Location
Upper Right
Upper Left
Quarter Point
Total
I
0.34
0.19
0.28
II
0.44
0.39
0.31
III
0.27
0.39
0.41
IV
0.15
0.31
0.44
1.19
1.28
1.44
33
When the inlet pressure was increased to 25 psi the acquired flow rates improved greatly. Each
individual section gathered enough water, and the minimum flow rate for the total of all areas
met the ASTM standard. At an internal pressure of 25 psi and 12 in. away, the spray rack
system meets the flow rate requirements.
Calibration data for an inlet pressure of 25 psi.
Captured Water in (L/min)
Calibration Box Section
Calibration
Location
Upper Right
Upper Left
Quarter Point
Total
I
0.44
0.25
0.31
II
0.49
0.43
0.36
III
0.35
0.43
0.45
IV
0.25
0.37
0.48
1.52
1.48
1.59
At an internal pressure of 30 psi all of the flow rates stayed within the tolerances of the ASTM standard.
Each individual area and the total of the areas met all the requirements. It can be concluded that at 30
psi and 12 in. of separation between the nozzles and the test specimen the spray rack meets all of the
constraints to conduct a water penetration test set forth by the ASTM E 1105-00 standard.
Calibration data for an inlet pressure of 30 psi.
Captured Water in (L/min)
Calibration Box Section
Calibration
Location
Upper Right
Upper Left
Quarter Point
Total
I
0.43
0.26
0.32
II
0.50
0.44
0.38
III
0.39
0.44
0.50
IV
0.27
0.40
0.50
1.58
1.54
1.70
34
APPENDIX C: OPERATION MANUALS
Overview
In order to complete a successful water penetration test to conform to ASTM standards, the
spray rack must be calibrated. At a test site, the rack must be assembled and set up at the
same settings used to calibrate the rack. The following instructions describe the necessary
procedures to assemble and calibrate the spray rack in order to complete a successful water
penetration test.
Spray Rack Assembly and Testing

Take all of the parts of the spray rack and lay them on the ground.

Set the three horizontal spray pipes in the general area that they will be connected to
the vertical supply pipe (i.e. set them 2.25 ft. apart vertically).

With the nozzles facing the ground, connect the quick release copper couplings of the
vertical pipe to the horizontal pipe inlets.

Maintain the form of the spray rack by placing it gently with the nozzles on the ground.

Fasten the aluminum vertical supports toward the outside of the rack configuration,
making sure that the top of the vertical supports (labeled in red) are located at the top
of the rack.

Install the water supply (garden hose) to the inlet of the rack, making sure that the
connection is tight to eliminate pressure losses due to leaks.

Remove the rack from the ground and set it upright, resting on the bottom of the
vertical supports.

Align the window spacers in their respective locations: two on the top horizontal pipe,
and one ¾ down the vertical pipe. Set the telescoping tubing at the required distance to
achieve 12 inches of space between the nozzles and the test specimen.

For specimens that are above the first floor of the building use ropes to suspend the rack
to the correct elevation.

For specimens on the first floor of the building, acquire the spray rack stand. Determine
the necessary height elevation needed, and set the stand at that height. Connect the
35
carabiners of the stand to the hanging mounts and raise the rack to the appropriate
height.

When the spray rack is located in the correct location, adjust the inlet throttling valve
until the pressure gauge on the rack reads the necessary pressure determined during
calibration to meet the required flow rates, begin the test.
Calibration of the Spray Rack System

With the spray rack assembled via the instructions above, use the spray rack stand to
hold the rack in place at ground level.

Position the calibration box vertically along the calibration stand by loosening the hose
clamps and sliding to the appropriate location. Follow this procedure for the graduate
container rack so that it is fastened just below the calibration box.

Place each of the calibration box hoses into the individual graduated containers by using
the Velcro tape.

Move the calibration stand and assembly to the calibration locations outline in the ASTM
standard.

Open the inlet throttling valve and allow water to impinge upon the calibration box.
When water begins filling the graduated containers begin timing the process.

After adequate water has been gathered in each container stop the timer, and turn off
the rack. Let the water drain from the box sections before making measurements.

Record the amount of water collected in each container and divide it by the time it took
to fill them, this method will result in obtaining a L/min measurement for each section of
the calibration box.

Validate that the flow rates from each section, and the total of all sections of the
calibration box, fall within the required flow rates as outline in the ASTM standard.

Record the inlet pressure that the measurements were made, this is the pressure that
must be used when a water penetration test is carried out on a job site.
36
APPENDIX D: PRODUCT DATA SPECIFICATIONS TABLE
MH = Morrison Hershfield
□□ Medium
□□□ High
Customer
Metric
Target
Target Basis
Verification
Notes
Reliability
MH
cycles
≥ 1000
cost effective
testing
3 tests/week
Portability to site
MH
vehicle size
required to
transport
easier/more
cost effective
to transport
end user
feedback
□□□
Portability to test
subject
MH
lbs/outer
dimensions
small
pickup
truck
average
person
can carry
efficiency
end user
feedback
□□□
□□
Ease of Operation
MH
-
-
-
end user
feedback
Weight (heaviest
component)
MH
lbs
< 50
portability/
fatigue
end user
feedback
□□
Service Life
MH
years
≥5
MH
testing
□□
Durability
MH
shock
loading
10G
SELF
Abaqus
Environment
easy to operate
consistently with
minimal training
Priority
Water
MH
surface
treatment
corrosion
resistant
SELF
end user
feedback
Operation
Temperature
MH
degrees °F
35-105
SELF
testing
□□
Suspension forces
SELF
10G
consistent
operation
end user
feedback
□□
Safety
Performance
Requirements
□ Low
Frame Integrity
MH
10G
SELF
Abaqus
□□□
Handling
MH
-
-
-
□□□
factor of
safety
factor of
safety
-
□□□
withstand industrial
stresses, impact,
□□□
handling, transport
□
37
MH = Morrison Hershfield
Documentation
Maintenance
Company Codes and
Materials
Constraints Standards
Installation
Requirements
□ Low
□□ Medium
□□□ High
Customer
Metric
Target
Target Basis
Verification
Notes
Setup Complexity
MH
setup time
(in hrs)
< 5 min
MH/SELF
end user feedback
setup should be
intuitive
Manpower required
(ground floor setup)
MH
# people
1
MH/SELF
end user feedback
□□□
Manpower required
(above ground
setup)
MH
# people
2
MH/SELF
end user feedback
□□□
Frame
SELF
USD
< 550
SELF
yes/no
corrosion resistant
□□
Other
SELF
USD
< 450
SELF
yes/no
corrosion resistant
□□
MH/SELF
gallons
ft2*hour
>5
ASTM
requirement
testing
SELF
USD
< $1500
MH
yes/no
MH/SELF
in2
14400
test area
testing
Serviceable in field
MH
yes/no
yes
SELF
end user feedback
□□
Replaceable
components
MH
yes/no
yes
SELF
end user feedback
□□
MH/SELF
difficulty
easy
SELF
end user feedback
□□
PDS
self
deadline
2/8/2010
PSU
documentation
□□
Progress Report
self
deadline
3/8/2010
PSU
documentation
□□
Final Report
self
deadline
5/31/2010
PSU
documentation
□□□
Timeline
self
deadline
PSU
documentation
□□
ASTM E1105-00
Budget
Coverage Area
Repair complexity
Priority
□□
□□□
needs to be
approved
□□
□□□
38
APPENDIX E: HOUSE OF QUALITY TABLE
Criteria
Customer
Weight
Design
MH/user
user
user
MH/user
MH/user
□□□
□□
□
□
□
□
□□□
□
□
□□□□□
□□□□□
□□□□
□□□□□
□□□□□
□□□□□
□
□
□
□□□□□
□
□□□
□□
□□□
□□□
□
Portability (to specimen)
10
6
6
7
9
9
MH/user
□
□□□□□
□□□□
□□□□□
□□
Maintenance (unrestricted)
3
MH
□□
□
□□□
□
□□□□□
Maintenance (field)
5
user
□□
□
□□□
□
□□□□□
Service Life
2
MH
□□
□
□□□
□
□□□□□
Customer
Requirements
Performance
Ease of Installation
Ease of Operation
Portability (to site)
Manpower Required
10 = high
Cost
Importance
Outer
Dimensions
Components
Engineering
MH = Morrison Hershfield
Low/Negligible □
High/Critical □□□□□
39
APPENDIX F: PART DRAWINGS
40
41
42
43
44
45
46
47
48
APPENDIX G: BILL OF MATERIALS
VENDOR
PURCHASER
3/4 x 10 pvc
$0.98
3
$2.94
HD
Andy
3/7/2010
Test app
Dauber
$1.31
2
$2.62
HD
Andy
3/7/2010
Test app
primer
$4.58
1
$4.58
HD
Andy
3/7/2010
Test app
cement pvc
$3.76
1
$3.76
HD
Andy
3/7/2010
Test app
3/4 cap pvc
$0.35
6
$2.10
HD
Andy
3/7/2010
Test app
3/4 elbow pvc
$0.69
1
$0.69
HD
Andy
3/7/2010
Test app
3/4 cross pvc
$1.70
2
$3.40
HD
Andy
3/7/2010
Test app
3/4 tee pvc
$0.33
2
$0.66
HD
Andy
3/7/2010
Test app
3/4 m adapter
$0.33
1
$0.33
HD
Andy
3/7/2010
Test app
sprink HD
$9.89
1
$9.89
HD
Andy
3/10/2010
Test app
3/4x10 pvc
$0.98
1
$0.98
HD
Andy
3/10/2010
Test app
3/4 f adapt pvc
$0.44
1
$0.44
HD
Andy
3/10/2010
Test app
1/2 elbow pvc
$0.90
1
$0.90
HD
Andy
3/10/2010
Test app
1/2 elbow (type 2) pvc
$0.69
1
$0.69
HD
Andy
3/10/2010
Test app
3/4 busing pvc
$0.38
2
$0.76
HD
Andy
3/10/2010
Test app
3/4 'M' adapter pvc
$0.33
1
$0.33
HD
Andy
3/10/2010
Test app
1/2x260 teflon tape
$0.98
1
$0.98
HD
Andy
3/10/2010
Test app
1/2x24 pvc
$0.79
1
$0.79
HD
Andy
3/10/2010
Test app
1/2 M adapter
$0.32
1
$0.32
HD
Andy
4/1/2010
Test app
3/4 cap pvc
$0.35
3
$1.05
HD
Andy
4/1/2010
Test app
3/4 tee sss
$0.33
1
$0.33
HD
Andy
4/1/2010
Test app
3/4 cross pvc
$1.70
1
$1.70
HD
Andy
5/8/2010
Rain rack
Pipe Bushing 3/4-1/2"
$2.37
12
$28.44
HD
Andy
PART
TOTAL
PURCHASE
TOTAL
Test app
Application
3/7/2010
DATE
#
MS = Metal Supermarkets AH = Ace Hardware
PRICE
HD = Home Depot
$30.97
$6.19
$3.08
$28.44
49
5/10/2010
5/10/2010
Rain Rack
Rain Rack
Copper Tube 3/4"
Copper Fem Adpt
$15.53
$5.81
3
12
$46.59
$69.72
HD
HD
Andrew
Andrew
5/10/2010
Rain Rack
3/4 Copper Tee
$2.39
18
$43.02
HD
Andrew
5/10/2010
Rain Rack
3/4 Copper Cap
$1.11
6
$6.66
HD
Andrew
5/10/2010
Rain Rack
8oz flux
$6.43
1
$6.43
HD
Andrew
5/10/2010
Rain Rack
Copper Female adpt
$3.54
1
$3.54
HD
Andrew
5/10/2010
Rain Rack
Pipe Cutter
$10.26
1
$10.26
HD
Andrew
5/10/2010
Rain Rack
3/4" valve
$9.87
3
$29.61
HD
Andrew
5/10/2010
Rain Rack
Shark Bit Clip
$1.54
2
$3.08
HD
Andrew
5/10/2010
Rain Rack
Shark Bite joint
$6.92
3
$20.76
HD
Andrew
5/10/2010
Rain Rack
1/2 lb solder
$13.81
1
$13.81
HD
Andrew
5/10/2010
Rain Rack
Interior brush
$1.95
1
$1.95
HD
Andrew
5/10/2010
Rain Rack
Exterior Brush
$3.46
1
$3.46
HD
Andrew
5/10/2010
Rain Rack
Copper male Adapter
$2.11
1
$2.11
HD
Andrew
5/10/2010
Rain Rack
3/4 Copper elbow
$1.31
3
$3.93
HD
Andrew
5/10/2010
5/10/2010
Misc
Misc
Arch Aluminum Tube (6063) square 1x1x12, 1/16"
Arch Aluminum Tube (6063) square (3/4)x(3/4)x12, 1/8"
$2.37
$2.56
1
1
$2.37
$2.56
McMaster
McMaster
Andy
Andy
5/10/2010
Misc
Arch Aluminum Tube (6063) square (3/4)x(3/4)x36, 1/8"
$6.23
1
$6.23
McMaster
Andy
5/10/2010
Misc
Arch Aluminum Tube (6063) square 1x1x3', 1/16"
$5.29
1
$5.29
McMaster
Andy
5/10/2010
Misc
Release pin W/lanyard, 3/16", 1.3" Usable length
$3.92
3
$11.76
McMaster
Andy
5/10/2010
Misc
Brass Spray Nozzle, 3/8" NPT Male, 2gpm@40psi, 120 deg
$10.19 12
$122.28 McMaster
Andy
5/12/2010
Rain rack
Butane
$5.99
1
$5.99
4th Store
Andy
5/17/2010
Calibration Box
Aluminum Sheet (6061) 3x4'
$68.36
1
$68.36
MS
Andrew
5/17/2010
Misc.
Aluminum Plate (6061) 1x2'
$44.86
1
$44.86
MS
Andrew
5/17/2010
Calibration Box
Aluminum Square Tube (6061) 1.5x1.5x72
$26.36
2
$52.72
MS
Andrew
5/17/2010
Misc
Aluminum flat (6061) .1875x.75x72
$4.00
4
$15.98
MS
Andrew
5/17/2010
Rain Rack
Aluminum Tube Round (6061) .75x48, 0.049"
$13.78
1
$13.78
MS
Andrew
5/17/2010
Rain Rack
Aluminum Tube Round (6061) .625x48, 0.058
$19.29
1
$19.29
MS
Andrew
5/17/2010
Misc.
Aluminum Plate (6061) 1x1', 0.5"
$43.50
1
$43.50
MS
Andrew
5/18/2010
5/18/2010
Calibration Box
Calibration Box
1/4 Barb
3/4 cop cplg
$1.48
$0.87
1
2
$1.48
$1.74
HD
HD
Andrew
Andrew
$264.93
$28.21
$5.99
$258.49
$20.94
50
5/18/2010
5/18/2010
5/18/2010
5/18/2010
5/18/2010
Calibration Box
Rain Rack
Rain Rack
Calibration Box
Calibration Box
Microtube
15" velcro
23' velcro
swivel
cop male adp
$4.07
$3.96
$3.46
$4.12
$2.11
1
1
1
1
1
$4.07
$3.96
$3.46
$4.12
$2.11
HD
HD
HD
HD
HD
Andrew
Andrew
Andrew
Andrew
Andrew
This box
tabulated
on
previous
page
5/19/2010
Calibration Box
Graduated Pitcher
$8.75
4
$35.00
Scientific
Andrew
$35.00
5/21/2010
Rain Rack
Brass Nozzle, 1/8" NPT Male, 0.5 GPM @40 PSI, 120Deg
$7.52
12
$90.24
McMaster
Andy
5/21/2010
Rain Rack
Brass Hex Reducing Bushing 3/8" Male X 1/8" Fem
$1.00
16
$16.00
McMaster
Andy
5/21/2010
Rain Rack
Brass Nozzle, 1/4" NPT Male, 1 GPM @40PSI, 120Deg
$8.02
12
$96.24
McMaster
Andy
5/21/2010
Rain Rack
Brass Nozzle, 1/8" NPT Male, 0.7 GPM @40 PSI, 120Deg
$7.52
12
$90.24
McMaster
Andy
5/21/2010
Rain Rack
Brass Hex Reducing Bushing 3/8" Male X 1/4" Fem
$1.49
16
$23.84
McMaster
Andy
5/24/2010
Calibration Box
JB Weld
$19.47
1
$19.47
AH
Luke
5/25/2010
Rack Stand
Aluminum Pipe (6061) 1.25x72"
$27.17
1
$27.17
MS
Andy
5/25/2010
Rack Stand
Aluminum Tube (6061) 1.25"x108", .125" thickness
$37.16
1
$37.16
MS
Andy
5/26/2010
Calibration Box
Combo Pack
$1.41
1
$1.41
HD
Andrew
5/26/2010
Calibration Box
Plastic Baggds
$0.98
1
$0.98
HD
Andrew
5/26/2010
Rain rack
1/4x2" lag screw
$0.46
1
$0.46
HD
Andrew
5/26/2010
Rain rack
1/4x2x1/2" H bolt
$0.76
1
$0.76
HD
Andrew
5/27/2010
Calibration Box
Rubber washer (4) 1/4"
$0.83
2
$1.66
HD
Andy
5/27/2010
Misc
Shipping parts back
$9.70
1
$9.70
USPS
Andy
5/27/2010
Rain Rack
Leg Tip, black rubber, 1"
$0.69
6
$4.14
AH
Andy
5/27/2010
Rain Rack
Aluminum bulk (used for supports)
$6.50
6
$39.00
AH
Andy
5/27/2010
Rack Stand
Eye Bolt
$7.49
2
$14.98
AH
Andy
5/27/2010
Rack Stand
16 gauge 11/2 dia squar tubing pl
$0.69
3
$2.07
AH
Andy
5/27/2010
Calibration Box
Hose Clamp
$4.79
2
$9.58
AH
Andy
5/27/2010
Rack Stand
2 1/2" snapper
$4.19
2
$8.38
AH
Andy
5/27/2010
Rack Stand
Spring Snap link
$4.99
2
$9.98
AH
Andy
5/27/2010
Rack Stand
1x8 glv nipple
$3.79
1
$3.79
AH
Andy
5/27/2010
Rack Stand
1" Galv Tee
$4.19
1
$4.19
AH
Andy
5/27/2010
Rack Stand
nuts and washers
$1.53
2
$3.06
AH
Andy
5/27/2010
Rack Stand
nuts and washers
$2.19
2
$4.38
AH
Andy
$106.24
$19.47
$64.33
$3.61
$1.66
$9.70
$117.85
51
5/27/2010
5/30/2010
Rack Stand
Calibration Box
Large Hex Bolt
Stopwatch
$7.15
$7.99
2
1
$14.30
$7.99
AH
Fred Meyer
Andy
Andrew
5/30/2010
Calibration Box
Auto Epoxy
$4.29
1
$4.29
Fred Meyer
Andrew
5/30/2010
Calibration Box
Caster wheels
$4.49
1
$4.49
HD
Andy
5/30/2010
Rain rack
Water Gage
$10.68
1
$10.68
HD
Andy
5/30/2010
Calibration Box
blk 5/8" leg tips
$1.69
1
$1.69
AH
Andy
5/30/2010
Calibration Box
Tip Leg vynl blk 1/2"
$1.49
1
$1.49
AH
Andy
5/30/2010
Calibration Box
Round pad 1.5"
$3.29
1
$3.29
AH
Andy
5/30/2010
Rain rack
16 gage 11/4 dia squar tubing
$0.99
4
$3.96
AH
Andy
5/30/2010
Rain rack
Wet/dry 9x11 150 grit sandpaper
$0.99
3
$2.97
AH
Andy
5/30/2010
Rain rack
Standard 9x11 150 grit sandpaper
$1.69
2
$3.38
AH
Andy
5/30/2010
Rain rack
Spray paint gray primer
$6.99
2
$13.98
AH
Andy
5/30/2010
Rain rack
Spray paint olive
$4.79
2
$9.58
AH
Andy
5/30/2010
Rain rack
Spray paint smoke gray
$4.49
2
$8.98
AH
Andy
6/1/2010
School
Capstone Poster
$65.25
1
$65.25
Kinko's
Andy
6/1/2010
Calibration Box
Scrap glass (acrylic)
$4.00
1
$4.00
AH
Andy
6/1/2010
Rain Rack
Metric Fasteners
$0.38
6
$2.28
AH
Andy
6/1/2010
Calibration Box
11 gage 11/2 dia square tubing plug
$0.79
4
$3.16
AH
Andy
6/1/2010
Calibration Box
Velcro strip 18" black
$3.99
1
$3.99
AH
Andy
6/1/2010
Rain Rack
Lacquer Gloss
$6.49
2
$12.98
AH
Andy
$12.28
15.17
$49.32
$65.25
$26.41
Grand Total $1173.53
Purchaser
Andrew
$595.25
Andy
$558.81
Luke
$19.47
Returned for credit, not included in price
52
APPENDIX H: ASTM E1105-00 STANDARDS
53
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55
56
57