HDPE Pipe

1. SWOT Analysis HDPE Pipe March 26, 2009 Jeffery Hite, Director Technical Promotions, Rinker Materials Concrete Pipe Division www.concrete-pipe.org

2. 2 Confessions from two former HDPE Pipe Engineers “I’m afraid our new advertising budget will allow only for fooling some of the people some of the time.” www.concrete-pipe.org

3. What’s in my right hand? www.concrete-pipe.org

4. High Density Polyethylene Pipe Producers www.concrete-pipe.org

5. The Two as One Concept • ADS bought out Hancor • This one company will play itself as two different companies • Two websites • Two products (Green and Blue Stripes) • Acceptance • This one company will play itself as one company • National Level • Speaks for entire industry • They will play themselves either way. Strengths www.concrete-pipe.org

6. ADS/Hancor plan on Attack • Follow the path of least resistance • Path 1- Seek product approval in smaller municipal markets and move up to larger ones • Path 2- Political Pressure • Path 3- Developer Route • Path 4- Test Project www.concrete-pipe.org

7. National Plan of Attack • Adjacent States • Political • TRB, AASHTO, and ASTM www.concrete-pipe.org

8. Deflection • Post Installation Deflection Testing (laser profiling and mandrels) • Achilles' Heel For HDPE Pipe Weaknesses www.concrete-pipe.org

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10. ME VT WA MT ND MN NH NY OR WI MA ID MI RI SD WY CT PA IA OH NJ NE IN IL DE MD WV VA UT CO NV MO CA KS KY NC TN OK AR SC AZ NM MS GA AL AK LA TX FL www.concrete-pipe.org

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13. UTA Laser Video Program • University of Texas at Arlington • Performed Research in 7 States • Texas, Minnesota, Virginia, North and South Carolina, Kansas and Missouri • Study released in six states • Texas, North Carolina, Virginia, Minnesota, Missouri, and Kansas • Pending States • Florida, California, Ontario, Colorado www.concrete-pipe.org

14. Kansas Minnesota Missouri Virginia N. Carolina Texas S. Carolina • North Carolina: • 6 Sites • 11 Pipes • South Carolina: • 4 Sites • 6 Pipes • Virginia: • 8 Sites • 21 Pipes • Minnesota: • 9 Sites • 31 Pipes • Texas: • 9 Sites • 22 Pipes • Kansas: • 2 Sites • 8 Pipes • Missouri: • 4 Sites • 13 Pipes Total of 106 pipes over 38 sites www.concrete-pipe.org

15. Excessive Deformation • Change in pipe diameter calculated from Variance of expected diameter • Maximum of X Deformation, Y Deformation and Ovality is considered as the maximum deformation • Limit of 5% deformation adopted for excessive deformation definition • Some pipelines showed as much as 21.8% deformation www.concrete-pipe.org

16. Excessive Deformation X Diameter Deformation = 11.7% Y Diameter Deformation = -15.8% X Diameter Deformation = 10.5% Y Diameter Deformation = -16.1% (Texas) (Virginia) www.concrete-pipe.org

17. Example of Deformation Graph (Texas) Maximum Deformation of the pipeline =19.5% a) b) www.concrete-pipe.org

18. Summary of Observed Failures www.concrete-pipe.org

19. 19 Results so far… • 106 pipelines. • 38 sites in six states. • 17,985 feet of pipe. • 100% suffered from one or more failure modes. • 70% suffered from excessive deflection. www.concrete-pipe.org

20. Installation • It doesn’t do what it is suppose to do • Usually, over half of the HDPE pipe installations do not live up to its expectations • Problem is no one is checking and notifying • Excuses • Foot dragging • Hard to inspect • Things are changing www.concrete-pipe.org

21. This is how the HDPE Pipe handle this • Post Installation- not necessary • Let us provide mandrels • If there is a problem- it is not our fault • Shift the blame- contractor responsible for installation, we guarantee materials. • We will help out- let’s provide you with some free pipe with a promise not to tell anyone. www.concrete-pipe.org

22. Most InstallationsHave Issues Use Our Mandrels(Base Diameter) Few Inspectors LookFor Issues Blame The Contractor Process Weakness HDPE Solutions Difficult / ExpensiveTo Install Deflection Is NotA Problem www.concrete-pipe.org

23. What Diameter Is It? • 5% Base = 8.2% Actual(for this example) • Different Manufacturers Vary www.concrete-pipe.org

24. If none of the previous stuff works • Take our free replacement pipe. • Our warranty only covers material and not labor or damages. • We will provide an extended performance bond. • Sign this non-disclosure agreement. www.concrete-pipe.org

25. Other Major Weaknesses • Complicated Design Method • Oxidation and Stress Cracking • Failures and Lawsuits • Natural Gas Prices • Key Personnel Getting Old www.concrete-pipe.org

26. Complicated Design www.concrete-pipe.org

27. TL = Factored Thrust per unit length (kip/ft) Do = Outside diameter of pipe (ft) PF = Factored Vertical Crown Pressure (ksf) Fcr = Critical Buckling Stress (ksi) R = Radius to centroid (in) Aeff = Effective Area (in2/ft) B’ = Nonuniform stress distribution factor Rw = Water Buoyancy Factor s = Soil Stiffness Resistance factor MS = Constrained Soil Modulus (ksi) E = Modulus of Elasticity (ksi) I = Moment of Inertia (in4/in) H = Height of Cover s = Unit Weight of Soil EV = Earth Load Modifier EV = Earth Load Factor VAF = Vertical Arching Factor PSP = Earth Pressure EV = Water Load Factor PW = Water Pressure EV = Live Load Modifier EV = Live Load Factor CL = Live Load Distribution Coefficient PL = Live Load Pressure Aeff =Effective Area of Pipe Wall W = Spacing of Corrugation Ag = Gross Wall Area Within the Length of One Period εbu(max) = γB εc Fu = Long-Term Tensile Strength γB = 1.5 www.concrete-pipe.org

28. Stress cracking, oxidation, & finished product testing • Stress crack resistance testing is being upgraded. • Oxidation testing is still not in AASHTO. • No testing currently for finished product. www.concrete-pipe.org

29. Results of Oxidative Induction Time (OIT) values of 14 new HDPE corrugated pipes NCHRP Report 429 www.concrete-pipe.org

30. PPI Presentation to AASHTO 2002 www.concrete-pipe.org

31. PPI Presentation to AASHTO 2002 www.concrete-pipe.org

32. SERVICE LIFE OF HDPE DRAIN PIPE: A REVIEW OF THE RECENTLY PROPOSED SPECIFICATION AND AN ALTERNATIVE APPROACH TO ACCELERATED TESTING Alexander Chudnovsky, PhD,, O. Manuel Uy, PhD, and Paul D. Wienhold www.concrete-pipe.org

33. Failures, costs, key personnel • Failures and Lawsuits • Costs • Bench Strength www.concrete-pipe.org

34. More Weaknesses • Time and Temperature Dependent Strength • Flammability • Flotation www.concrete-pipe.org

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37. SAFETEA-LU • Downturn = use lowest cost pipe material. • Service Life • Guide national research in favor of HDPE. Opportunities www.concrete-pipe.org

38. Recycled resins are green. • Recycled resins are cheaper. Opportunities www.concrete-pipe.org

39. RCP is vulnerable to cracking and corrosion concerns. Opportunities www.concrete-pipe.org

40. Opportunities www.concrete-pipe.org

41. UTA • Increased Inspection • ACPA • Reliance on Natural Gas • New Flexible Products • 3rd Party Research • Green Concerns The Dirty Truth About Plastic 04.18.2008 BPA and other plastics may be as harmful as they are plentiful. by Jill Neimark , published in Discover Magazine in May 2008 Threats www.concrete-pipe.org

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43. Results so far… • 106 pipelines. • 38 sites in six states. • 17,985 feet of pipe. • 100% suffered from one or more failure modes. • 68% suffered from excessive deflection. www.concrete-pipe.org

44. This will unquestionably raise the bar for concrete pipe expectations. www.concrete-pipe.org