Fusible Polyvinyl Chloride Pipe Provides Owner with a Monolithic ...

Hawaii Section /American Water
Works Association
i
Annual Conference – 19 May 2010
AIRPORTS DIVISION SOUTH RAMP WATER LINE
PROJECT – FUSIBLE C-900 ®
Gaudencio “Dennis” Lopez
Oahu District Engineer for the Hawaii Dept. of
Transportation, Airport Division
Rob Craw
Underground Solutions, Inc.

HDOT Background with Fusible PVC
TM
• The District has installed two major projects with Fusible C-900
®
to date
• Kalewa Force Main Upgrade (1200 LF) - 2008
• Dillingham Airfield New Waterline Installation (800 LF) – slipline - 2009
• Rehabilitated Lagoon Drive culvert crossings on an existing 14
inch force main

Project Background
• The South Ramp at the Honolulu International Airport (HNL)
supports various commercial aviation activities including air
cargo, general aviation, flight tours, etc.
• The HNL water system is owned and operated by the
Department of Transportation
• The South Ramp pp portion of the HNL system comprises of a 16
inch main on Lagoon Drive that feeds 12 inch secondary off
Lagoon Drive. These arterial mains are looped together by
integrating an 6 inch cast iron line originally installed by the US
Navy.

SITE LOCATION

Location of Existing Waterline To Be Replaced
EXISTING 6 INCH WATERLINE

Project Background
S. Ramp Circa 1940’s
• The 6 inch water line:
• Provided water to the former
Navy seaplane hangars and
docks
• Installed in the 1940s
• 6 inch cast iron 6 inch potable
water
• 2300 feet
• Buildings were constructed
over the existing line or
within ihi near proximity i of
building foundations
• Concern of scale build-up up
potentially reducing ID and
increasing friction
• Increasing frequency of
breaks in the subject line
Exhumed S. Ramp Pipe

Design Considerations
Design:
• Shimabukuro, Endo & Yoshizaki, Inc.
• Pacific Geotechnical Engineers
Open Trench & Horizontal Directional Drilling
• Minimal Disruption
• Geotechnical Consideration
• Cost ($859,475.00 design estimate)
Open Trench
• Reasonable waterline depth
• Cost ($678,795.00 design estimate)
• Intrusive Construction Activity

Project Goals and Challenges
Goals:
• Upsize the existing line from 6 to 8 inches
• Mitigate potential for hydrocarbon permeation
• Reduce disruption to airfield and commercial activities
Challenges:
• Waterline crosses active taxilanes, roadways and parking lots
• Alignment in close proximity of existing buildings and utilities
• Undiscovered abandoned utilities
• Relatively shallow groundwater table 5.5 to 7 feet bgs

Line Replacement Layout

Ground views
SURVEYING ALIGNMENT
OFFSETS NEAR TAXILANE 4
TRENCH SAWCUT BY AIR
SERVICE HAWAII

Basis of Design Summary:
• Replace 70 year old section of 6-inch cast iron pipe and upgrade
with 8 inch PVC pipe. This pipe section provides a loop
network for the Honolulu International Airport South Ramp
• Design Requirements and dCh Challenges
• Potential for contaminated soils or groundwater due to
mobile fuel farms and adjacent live fuel lines
• Desire to remove gaskets/segmented pipe and limit the
amount of joints in the system
• Pipe system must be resistant to hydrocarbon permeation
• Construction will occur over active taxilanes and roadways
• Ability to deal with unforeseen abandoned utilities
• Post Design Considerations
• Pipe System must be resistant to Oxidative Degradation in
the presence of chlorine based disinfectants (Groundwater
Rule, recent studies)

• Fusible C-900
®
Fusible C-900
®
• Leak free, restrained joint pipe systems
• Trenchless installation modes that reduce contractor
costs
• Rehabilitation capabilities for intractable high pressure
water pipe pp
applications
• More than 1000 successful projects installed to
date
• In over 43 states, Canada and Mexico
• Over 2000 HDD’s (directional drills) completed
• Over 4000 separate pull-in instances (HDD, Slipline,
Pipe Burst, Open-Cut)
• Products meet all industry standards
• AWWA C900, C905, NSF-61, NSF-14, PPI-TR2, ASTM
Cell Classification 12454
• Utilizes stock PVC fittings
• Available in all water industry configurations
• Quality certified by industry-leading PVC pipe extruders
to AWWA standards

The Underground Solutions ® PVC Fusion Process: Utilizes
Industry Standard Fusion Equipment
Internal and External Bead Removal is Optional – friction losses are negligible (‘C’-factor of 150) and
are significantly ifi less than mechanically joined pipe (i.e. for 8” DR18 with 1000gpm in a length of 1000LF,
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)

Fusible C-900
® , Fusible C-905
® And FPVC:
Fusion Process Is Tightly Controlled
• Qualified fusion technicians are trained and
retrained every year by Underground
Solutions
• Initial 3 day course
• Fusion equipment must meet minimum
company 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
Fusion Date
Nov. 29, 2007
Project No. 30111
Project Name
Myrtle Beach 20" Force Main Diversion
Jobsite Location
Myrtle Beach, SC
Pull No.
Project Engineer
Eric Kerner
Fusion Technician Eric Kerner
PIPE DETAILS
Joint No. Pipe Dia. (in) Pipe DR Color
Extruder
Pipe Description
20004
20 DR 25 Green
NAPCO
FPVC
EQUIPMENT IDENTIFICATION
Piston
Data Logger Serial IR Pyrometer
Fusion Machine Identification
Heat Plate Serial ID
Area (in 2 )
No.
Serial No.
T-900
15.32
C09247
MDL3-0241 21462810604-1172
A. Pressures (psi) B. Ambient Conditions / Start Time
Heat
131
Temp. (°F)
57
Fusion
564
Weather
sunny
Drag
50
Start Time
10:52 AM
End Time 11:29 AM
C. Heating Plate Temperature & Extrusion Marking
Left Face Temperature - °F Right Face Temperature - °F
412
410
12:00
402 9:00
3:00 403
6:00
399
Piv vot
12:00
402 9:00
3:00 395
6:00
399
Joint Number
20004
15 Sept 07 @ 11:23 12 Nov 07 @ 17:47
188
235
Record extruder pipe marking (near fusion joint) and pipe length above.

San Francisco International Airport
• 750 linear feet of Fusible C-900
®
• 12” DR14 for new potable water
line
• Fusible C-900
® selected for its
ability to be installed in aggressive
soil and groundwater conditions -
petroleum hydrocarbons present
• Ability to withstand oxidative
degradation of chlorine based
disinfectants

Design Elements
ROADWAY CROSSING
UTILITY CROSSING
TAXILANE CROSSING
VALVES & ARV’S (NOT
SHOWN)
SERVICE RECONNECTION
(NOT SHOWN)
STA 0+00
STA 23+00

INCORPORATION OF FUSIBLE C-900 ® AS BASIS OF DESIGN
• IMPERMEABLE TO JET FUEL AND AVGAS DUE TO PROXIMITY TO
FUEL STORAGE AND HYDRANT SYSTEMS.
ABOVEGROUND
STORAGE TANK
AND FUEL
TANKER STORAGE
AREA

Research indicates that HDPE can be degraded by
common water disinfectants leading to Stage III
“end of life failure”
• Polyethylene is a polyolefin family
plastic – which oxidizes without
the aid of antioxidants that are
added to the HDPE formulation
• Over 20 research papers published
since 2004 document the failure of
HDPE (PE80, PE100) pipe in the
presence of water disinfectants –
Stage III failure resulting from
oxidation (rapid antioxidant
consumption) and polymer chain
scission
i
• North American standards (ASTM
and AWWA) do not give guidance
on a design factor to account for
this newly documented
phenomenon
• Life expectancies do not consider
Stage III failure
• Safety factors do not consider
oxidative failure mode
• PVC has been demonstrated to be
resistant to oxidation due to water
disinfectants
Hoop Stress
Stage III oxidative induced cracking polyolefin family pipe – Choi 2008
Chemical Aging
Premature Stage
III Failure
Time
Hydroperoxide decomposition of polyethylene under
attack by chlorine dioxide – L. Audouin et al. 2007

Continuing Research Demonstrates that Aged HDPE (in
Chlorinated Water) Allows Dramatically Higher Diffusion
of Toluene: AWWA Research Foundation Project # 4138
OIT Level
Carbonyl
Id Index

Incorporation of Fusible C-900 ® as Basis of
Design
• Reduction of gaskets through 40’ pipe length and fused joints
• Ability to use DI Fittings
• Use of restraint couplings with Fusible C-900
® to minimize thrust
blocks

Incorporation of Fusible C-900 ® as Basis of
Design
• UTILIZE BEND RADIUS OF PIPE THEREBY REDUCING FITTINGS
VERTICAL BEND
HORIZONTAL BEND

Overall Construction Sequencing
• Bid Open 18 June 2009
• State Project Number BO1906-73
• Awarded to Ideal Construction, Inc. $624,103.00
Fusion Contractor Briant Construction
Material: FPVC, Underground Solutions Inc.
• State Project Manager: Keith Ishinaga
• Construction period December 2009 to March 2010
• Challenges:
Discovery of abandoned electrical jacket (transite pipe)
Sensitive Construction Zone
• Solutions:
Take advantage of available bend radius and restraint nature of FPVC
Coordination with tenants and operations

Construction Challenges
• Horizontal/Vertical re-alignment
• Discovery of abandoned jacket interfering with design alignment and
space is available to re-align pipe.
• Took advantage of the bend radius of Fusible C-900
® pipe to reduce the
need of fittings
• Use of offset fitting (8x18) to dive under abandoned utility jacket and
utilize bend radius of pipe after jacket to return to planned pipe invert
thereby eby reducing the need for a second fitting
Abandoned Electrical
Jacket (transite pipe)
Pipe Bend Around Portion of Electrical
Jacket left in‐place

Fusible C-900
® Layout – Joining pre-fused
sections to speed construction in sensitive i
areas

Fusible C-900
® Layout – Fused Joint ID
• All fused joints
were recorded by
the fusion
contractor and a
fusion report will
be submitted to the
DOTA
• All fused joints
were GPS surveyed
by the DOTA prior
to backfilling to
correlate the joint
report with its
physical field
location

Fusible C-900
® Layout – Transport of Fused
Sections

Fusible C-900
® Layout – Installation of Toning Wire

Case Study Summary: Successful Project
• A70 year old section of f6i 6-inch cast iron pipe was replaced and
upgraded with 8 inch PVC pipe. This pipe section provides a
loop network for the Honolulu International Airport South
Ramp.
• Design and Construction Challenges
• Pipe system resistant to hydrocarbon permeation
• Pipe System resistant to Oxidative Degradation in the presence of
chlorine based disinfectants
• Construction over active taxilanes and roadways
• Discovery of unforeseen abandoned utilities
• Solution
• Design basis with Fusible C-900
® created a monolothic, restrained and
hydrocarbon resistant system
• PVC does not exhibit Oxidative Degradation due to chlorine based
disinfectants
• Minimize construction time in sensitive areas by quickly joining pre-
constructed fused pipe lengths
• Utilize available bend radius of Fusible C-900
® and restraint couplings
allows for changes in the alignment reducing the number of fittings and
the use of thrust blocks
• New 8 inch loop line has been tested and in service.
Project within budget and on time.

Questions?