Concrete Pipe Of the Future

1. 2014 ACPA Pipe School Houston TX Concrete Pipe Of the Future www.concrete-pipe.org

2. A Walk though our History The Beginning www.concrete-pipe.org

3. EBAYAntique Piece of 1st Concrete Sewer Pipe in N America 1842 Mohawk,NYItem condition:UsedEnded:Feb 02, 2014 16:20:54 PSTWinning bid:US $9.95[ 1 bid ]Shipping:Item location:Latham, New York, United States

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5. Item specifics • Condition: Used: An item that has been used previously. The item may have some signs of cosmetic wear, but is fully operational and functions as intended. www.concrete-pipe.org

6. Firsts! • 1905 – Reinforced Concrete Pipe produced www.concrete-pipe.org

7. Firsts! • 1930 – ASTM C75 Reinforced Concrete Sewer Pipe • – ASTM C76 Reinforced Concrete Culvert Pipe www.concrete-pipe.org

8. Firsts! • 1932 – ASTM C14 Unreinforced Concrete Sewer Pipe www.concrete-pipe.org

9. The formation of the American Concrete Pipe Association? • 1907 in Ames Iowa– Interstate Cement Tile Manufacturers Association • 1914 in Chicago – American Concrete Pipe Association www.concrete-pipe.org

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12. Improvements/Changes • Production Techniques • Quality • Joints • Liners • Materials • Standards • Training • Workforce www.concrete-pipe.org

13. What is Next? www.concrete-pipe.org

14. Our Current Concrete Products have FOUR main issues of concern for our Customers: • Product weight • Product length • Cracks (of any type) • Corrosion Resistance • Soil Infiltration • Our joints www.concrete-pipe.org

15. 15 Here is a list of a few of the things we are aware of that are currently happening to enhance our industries future………………YOUR FUTURE! www.concrete-pipe.org

16. Future CEMENTICIOUS MATERIALS CONCRETE Benefits or Goals: • Environmental, CO2 emissions and other greenhouse gases • Corrosion resistance • Curing crack reduction/elimination • Ductile concrete • Fatigue resistant concrete • Concrete products life span traits www.concrete-pipe.org

17. Future CEMENTICIOUS MATERIALS Options to Consider: CONCRETE • Portland cement types and continued research in Nano technology and improving on the formation of crystals in clinker and cement. • Varying heat of hydration cements. www.concrete-pipe.org

18. Future CEMENTICIOUS MATERIALS CONCRETE • One cement guru’s comments: “This cement company is trying to make clinker/cement that is MORE REACTIVE WITH Supplementary Cementicious Materials so that concrete producers can USE LESS OF IT.” (CEMENT) www.concrete-pipe.org

19. CONCRETE Future CEMENTICIOUS MATERIALS • Ground granulated blast furnace slag cement – few of us are using it now! • Fly ash types; the future of fly ash is uncertain. The quality and chemical makeup of the fly ash is its key to durability. • High CaO fly ashes don’t perform as well over the long term. With the threatened futures of thermal power plants, it is going to result in higher CaO (lower SO3) fly ash. www.concrete-pipe.org

20. Future CEMENTICIOUS MATERIALS CONCRETE • Geopolymer concrete made with NO Portland cement. Its fly ash and an activator chemical. Early strengths are low but later strengths are higher than we are getting. There are some fly ash dosage rate products (90%) for corrosion resistance. This is already being done in the USA. www.concrete-pipe.org

21. CONCRETE Future CEMENTICIOUS MATERIALS • Micro-Silica for corrosion protection…it has some dispensing health issue potentials. • Nano-Ceramics in Phenolic Acrylates with micro-fine minerals (They won’t tell us which ones) to benefit MANY concrete properties. • New products like Lafarge Ductal 54” tunnel pipe w/ 1.625” wall • Limestone cement – replacing clinker at 15% now. What about going to the future? www.concrete-pipe.org

22. CONCRETE Benefits or Goals: Future ADMIXTURES • Corrosion resistance…Let’s take our share of the sanitary sewer market back! • Self healing concrete • Higher strengths • Reducing product casting deformations • Reduced heat of hydration • Much lower permeability www.concrete-pipe.org

23. CONCRETE Benefits or Goals: Future ADMIXTURES • Chloride resistance • Sewer gas, microbe, and effluent chemical resistance • Micro crack control or elimination • Reducing energy costs and CO2 emissions www.concrete-pipe.org

24. CONCRETE Future ADMIXTURES Options to Consider: • Xypex, Conshield, and the numerous other groups working on this product research. • Rice hull ash • Admix to assure zero air is entrained in our concrete, if we want that. It gives an Extremely smooth finish. • Metakaolin (Fine Porcelain Clay) and GGBFSC to fill the void left from more restrictive environmental specifications on cement. • Superplastisizers that will yield warm weather strength results even when used in freezing temperatures. www.concrete-pipe.org

25. CONCRETE Future ADMIXTURES • Hyper Plasticizer Generation: • Polycarboxylate Ether. • Corrosion inhibitors influence many different concrete properties. Continuing research will likely give users, designers, and owners more confidence in their effectiveness. • Waterproofing admixtures to eliminate interior and exterior coatings. www.concrete-pipe.org

26. CONCRETE Benefits or Goals: Future ADMIXTURES • Alkali-Silica Resistance (ASR) • Weight reduction • Cost savings • Environmental concerns www.concrete-pipe.org

27. CONCRETE Benefits or Goals: Future ADMIXTURES • Harder, more dense, and less permeable concrete products. • Greater abrasion resistance • Higher strength concrete can equal the possibility of less reinforcement from reduced dead loads of our products. www.concrete-pipe.org

28. CONCRETE Benefits or Goals: Future ADMIXTURES • Maturity meters for curing strength prediction certainty. • Time domain reflectometry… A very cutting edge maturity metering system. • Curing chambers – we MUST catch up in our knowledge and research. Japan and Australia are using microwave curing chambers for their concrete curing. • Internal Curing; Increasing 28 day cure strengths and product durability using lightweight sand to cure concrete from the inside. www.concrete-pipe.org

29. CONCRETE Benefits or Goals: Future ADMIXTURES • Super Absorbent Polymer Admixtures are being developed for internal curing to eliminate the need for lightweight sand. • In Northern Europe: Mechanical Air Entraining. They use a hardened particle that can be added to the mix that will guarantee EXACT air content in the products. • High Strength Structural LIGHT WEIGHT Concrete. www.concrete-pipe.org

30. CONCRETE Benefits or Goals: Future ADMIXTURES • Reactive powder concrete is extremely workable, durable, and yields ultra strengths of 30,000 psi. • Concrete repair products that include fibers and special use admixtures for repairs. www.concrete-pipe.org

31. CONCRETE Benefits or Goals: Future ADMIXTURES • Weight reduction… Thinner wall design • Composite reinforcing products from NEW designs • Corrosion Resistance • Ductility – Flexible CONCRETE Pipe • Crack concerns: • Reinforcing Corrosion • Backfill soil infiltration into the pipe • Current research on thin wall pipe. • Lower carbon foot print for our products. www.concrete-pipe.org

32. New High Strength Steels: Future REINFORCING Options to Consider: • No Reinforcing…Our Michigan contractors won’t treat this properly. In Canada, their customers do a terrific job with it. We can make the pipe and many installations without reinforcing, but we must force that proper installation practices are followed. www.concrete-pipe.org

33. New High Strength Steels: Future REINFORCING • A Swedish company and other European companies have 1,500 Mpa (217,577 psi!!) tensile strength steels. • An American company is currently roll forming 1,300 Mpa (188,550 psi) tensile strength steels. • MMFX2 high strengths grade 100 (690 Mpa) corrosion resistant rebar already has an AASHTO specification in July 2012 for concrete reinforcing steel. AASHTO MP18/ASTM A1035 www.concrete-pipe.org

34. New High Strength Steels: Future REINFORCING • Hard Wire LLC has a high tensile steel reinforcement product that is based on steel- belted tire technology; using ultra high strength TWISTED steel wire cords. www.concrete-pipe.org

35. Future REINFORCING • Could we use post tensioning assembly for our concrete product reinforcing? • Could we only use fiber reinforcement in some circumstances? www.concrete-pipe.org

36. Steel Fibers • Coated Steel Fibers • Polypropylene Fibers • Poly Vinyl Alcohol Fibers • Fibers Combined With Welded Wire Fabric. • Machine Shop Millings.. GET CREATIVE!! • Galvanized Steel Fibers • Fiberglass Bars • New High Strength Steel Types: • Basalt Fibers or Bars • Carbon Fiber • Twisted Fishing Lines...(Stronger Than Steel)… Dream BIG!!! • Kevlar Fibers Future REINFORCING Fiber Types – Samples Are Being Passed Around www.concrete-pipe.org

37. Future REINFORCING • Not all fiber types will work… Some of us remember Applewood fibers failed in the US. • Bamboo fibers • Various chemical plasma cleansing of fibers. • Multiple blends including four or more of these products in the same mix design? • NACE International… the corrosion society; we must watch what practices they are working towards… Some may become useful. www.concrete-pipe.org

38. Benefits or Goals: Future JOINT DETAIL • The ACPA has a task group in action that is working on designs for new style and new achievable standards to have our joints considered as the best sewer joints available. www.concrete-pipe.org

39. Future JOINT DETAIL • The current joint design is too contractor sensitive. • New shapes of joint products and even new shapes of our products will require new gasket designs. • Can we make a great joint reinforcing with these new products? • Gasketed box culverts are taking over in some parts of the country. There is an ASTM Spec, C-1677 for this detail. • Gaskets are being put on Arch pipe, Elliptical pipe, and other precast shapes. www.concrete-pipe.org

40. Future JOINT DETAIL • New gasketed materials • Structures cured in the installed position? • Composite made with Materials other than concrete? possibly combine concrete, rubber, and plastics? • Concrete SOCK-PIPE? www.concrete-pipe.org

41. Benefits or Goals: Future PIPE LAY LENGTHS • Longer lay lengths will equal less joints, which is what our customers have been asking for. www.concrete-pipe.org

42. Benefits or Goals: Future WALL THICKNESS • Thinner walls equalmore pieces per load. Michigan allows 19 pieces and Ohio lets 7 pieces of 42” pipe on a truck load. • Thinner walls means smaller machinery for contractors’ and manufacturers’ handling. • Lower product costs. • Lower machinery and forming costs. • Member plant testing is currently being done. • Current Research By UTA. www.concrete-pipe.org

43. Future MACHINERY Processes Benefits or Goals: • The technology is improving everyday to help us make more products with a higher quality. Equipment such as computer controls, this technology turns old school in years instead of decades. We can’t continue to survive thinking like my grandfather did back in the 1930’s! • During the last economic recession, most companies wore out their equipment and replaced little of it. Now is the time, if products are going to change, to order machinery to manufacture the newly designed products. www.concrete-pipe.org

44. Benefits or Goals: Future Supervisory And Labor Skill Requirements • To continue to be the lead industry in underground drainage products, we must continue to use our best and most talented industry workers. There is no reason to need to change that positive outcome! • Product costs, to be more competitive with the cheaper competition; More profitable equates to better wages and more certain futures for all of us. www.concrete-pipe.org

45. Benefits or Goals: Future And Current RESEARCH • Sustainability and life cycle costing has not gone away. • Our industry has many companies, members, and researchers evaluating and designing new ways and new designs with equipment that has never been available. We have the most dedicated and talented staff in our association and on its committees. With their direction and focus, no competitive products stands to take our proven lead position. www.concrete-pipe.org

46. Benefits or Goals: Future And Current RESEARCH • We must not be afraid to follow our imaginations. We must however, remain very diligent and cautious to not venture off on our own and destroy the long standing reputation of our industry by following the lead of what I consider overzealous material sales people (ours and new suppliers) who want us to manufacture and deliver products before our association gets a chance to prove what we are doing is correct. www.concrete-pipe.org

47. Future And Current RESEARCH • How and who will validate all these new products being made? AASHTO and Academia will most certainly be reviewing work appropriately in the many combinations that are possible as we promote them. • We need to remain diligent in our industries cooperative efforts to lead these performance enhancing products and processes that will modify all our futures. We must know the compatibility of all these new tools in the long term; Just like the pharmacist must know prescription drug interactions. We will find out what all this research can or can’t do. www.concrete-pipe.org

48. ATTENTION!! • WE NEED ALL OF YOUR HELP TO KEEP ADVANCING OUR INDUSTRIES FUTURE. Our industry has the brightest potential due to the design technology and materials advancement available to us. • THE FUTURE IS NOW!!! The research community is not standing around waiting for us to tell them what we want. We must figure out our direction before its too late. • Times are changing and so must our industry. We can all continue to have exciting careers in this industry if we keep working together. www.concrete-pipe.org

49. ATTENTION!! • Production People: Trust your experience and instincts. Follow your and your people’s imagination! Our customers require and deserve the very best products available to them to stretch their infrastructure dollars. • You production people know what is possible and what is currently considered to be impossible, better than anyone else. Lets all put a great deal of our energy together and prove what fantastic things we can achieve with all these new technologies that are coming our way. www.concrete-pipe.org

50. What If We… www.concrete-pipe.org