Grantee Research Project Results
Final Report: Reduced Cost Sewer Pipe Relining Using Ultrasonic Tape Lamination
EPA Contract Number: 68D00240Title: Reduced Cost Sewer Pipe Relining Using Ultrasonic Tape Lamination
Investigators: Roylance, Margaret E.
Small Business: Foster-Miller Inc.
EPA Contact:
Phase: I
Project Period: September 1, 2000 through March 1, 2001
Project Amount: $69,959
RFA: Small Business Innovation Research (SBIR) - Phase I (2000) RFA Text | Recipients Lists
Research Category: Nanotechnology , SBIR - Pollution Prevention , Pollution Prevention/Sustainable Development , Small Business Innovation Research (SBIR)
Description:
During this Phase I program, Foster-Miller has developed techniques based on Ultrasonic Tape Lamination (UTL) to joining of plasticized PVC sewer liner material. This effort was undertaken in response to a need for environmentally sound and cost-effective methods for rehabilitation of aging water and sewerage pipe rehabilitation infrastructure. For this purpose, Foster-Miller worked with Ameron International, the Massachusetts Department of Environmental Protection (MassDEP) and the Massachusetts Water Resources Authority (MWRA) to evaluate the use of ultrasonic joining of liner materials. The use of ultrasonic joining has several significant advantages over the hot air field welding process currently used by Ameron. These advantages include the highly focussed nature of energy deposition during insonification, and the rapid generation of this localized heating through a combination of viscoelastic and frictional effects. Due to these advantages, ultrasonic welding methods allow rapid joining against the surface of a concrete sewer pipe which functions as a significant heat sink during conventional hot air welding, resulting in very long hot air welding times. The current hot air welding method also requires the use of a highly plasticized PVC "weld strip" in addition to the base material. This welding process advances at a rate of approximately 6 in./min, and requires two passes to complete the weld. Foster-Miller has demonstrated high strength ultrasonic welds in the plasticized PVC liner material using commercial off-the-shelf equipment, and has demonstrated weld times of 6 in. in 2.5 to 3 sec. In conjunction with our business partner Branson International, we have evaluated several alternate techniques and ultrasonic systems in order to identify a welding procedure and a field-deployable system based on modified commercial equipment that would provide the most energy, time and cost-effective solution to the current problem.The Phase I program sought to adapt and demonstrate existing Foster-Miller UTL technology from the fabrication of fiber reinforced thermoplastic aerospace components to the application of plastics joining in lined pipe installation and existing pipe rehabilitation. The principal goal was to achieve an order of magnitude increase in welding speed. Specific objectives included the following:
- Define the material and performance requirements for a range of pipe rehabilitation systems.
- Identify the UTL operating parameters necessary to process the selected materials.
- Demonstrate, through laboratory fabrication and testing, that the necessary joint performance can be achieved.
- Develop the system operating envelope for field applications.
- Design a complete ultrasonic joining machine for fabrication and use in Phase II.
- Develop cost projections for welding unit and potential time and cost savings
Summary/Accomplishments (Outputs/Outcomes):
Conclusions:
In summary, the Foster-Miller ultrasonic joining technique has exceeded the technical goals set for the Phase I program. The technology has been demonstrated against a realistic substrate, and has been shown to provide welds that meet the strength goals established by Ameron with joining times more than an order of magnitude shorter than the current method. Based on these results, Foster-Miller and Ameron propose to design and build a prototype field-deployable joining system and demonstrate its use in the field for installation of PVC liner materials.Journal Articles:
No journal articles submitted with this report: View all 1 publications for this projectSupplemental Keywords:
Infrastructure, sewer pipe repair, infiltration and inflow, I/I, ultrasonic welding., Scientific Discipline, Water, Civil/Environmental Engineering, Civil Engineering, Engineering, Engineering, Chemistry, & Physics, Environmental Engineering, Ultrasonic Tape Lamination (UTL), sewer pipe, infrastructure , Massachusetts Water Resources Authority (MWRA) , reliningSBIR Phase II:
Reduced Cost Sewer Pipe Relining Using Ultrasonic Tape Lamination | 2000 Progress Report | Final ReportThe perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.