Full Scale Testing

Part of ARPA-E Project: Rapid Encapsulation of Pipelines Avoiding Intensive Replacement (REPAIR)

Jonah Cooke — Tue, 15 Oct 2024 15:58:48 +0000

Part of ARPA-E Project: Rapid Encapsulation of Pipelines Avoiding Intensive Replacement (REPAIR) Jonah Cooke Tue, 10/15/2024 - 09:58

Approach

U.S. Department of Energy–supported, 3-year, multi-million-dollar project focused on gas distribution mains. The approach automates construction of a regulation-compliant, stand-alone internal replacement pipe (IRP) inside legacy mains using trenchless methods. It integrates smart structural coatings, new integrity/inspection tools, and 3D geospatial maps combining pipeline, adjacent-utility, leak, and coating-deposition data. A performance-based framework is used to establish pipe-replacement criteria and to validate a 50-year design life for IRP systems.

Results

A validated design basis demonstrates a 50-year design life for innovative IRP systems that do not rely on the host pipe. Clear performance criteria and acceptance thresholds for pipe replacement are established to meet utility and regulatory requirements. Prototypes and test datasets are produced for smart coatings, integrity/inspection tools, and integrated 3D mapping of mains and nearby infrastructure. Progress is shown toward a total cost target of $0.5–$1.0M per mile, inclusive of service disruptions.

Implications

Utilities can rehabilitate leak-prone legacy mains faster and with less excavation, reducing methane emissions and improving public safety. The performance criteria provide a repeatable, standards-ready pathway to specify and qualify IRP technologies across projects. Smart coatings and integrated mapping enhance long-term monitoring, risk prioritization, and lifecycle asset management. Achieving the cost target supports large-scale deployment and accelerates backlog reduction nationwide.

Project Team

Primary Investigator:

Brad Parker Wham

Shideh Dashti

Mija Hubler

CIEST Personnel: Patrick Dixon, John Hindman, Davis Holt, Cory Ihnotic, Katherine O'Dell, Kent Polkinghorne, Dustin Quandt, Yao Wang
Graduate Researchers: Jacob Klingaman, Sina Senji, Molly Sickler, Deeptesh Pawaskar
Undergraduate Researchers: Jonah Cook, William Flood, Coen Hines, Alyssa McCarthy, Ketan Kamat, Daniel Mascarenas, Samuel Mohnacs

Project Deliverables & Reports:

View ARPA-E's program description

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Evaluation of Gate Valve Flanges: Serrated vs Non-Serrated Under External Loading

Anonymous — Tue, 30 Apr 2024 22:09:33 +0000

Evaluation of Gate Valve Flanges: Serrated vs Non-Serrated Under External Loading Anonymous (not verified) Tue, 04/30/2024 - 16:09

Project Title: Evaluation of Gate Valve Flanges: Serrated vs Non-Serrated Under External Loading

Industry Partners: Denver Water

CIEST Personnel: Cory Ihnotic and Jessica Ramos

Primary Investigator: Prof. Brad Wham

Year: 2024

The intent of this study is to investigate the difference between a serrated faced flange connection and a non-serrated faced flange connection; mainly to determine whether one would leak sooner than the other. To evaluate this, a series of four-point bending tests with applied axial load were conducted on Mueller Resilient Wedge Gate Valves. The tested specimens were commercially available 6 in. (150 mm) diameter ductile iron pipe conforming to AWWA C600 standards, which were provided by Denver Water. Each type of flange connection (serrated or non-serrated) received two tests, each with displacement applied at a rate of 1 in. (25 mm) per minute. For the conducted tests, several points of interest were located including the site of the first and second leaks, and their respective leak rates to determine which of the connections had a more substantial failure.

Appreciation is extended to John Daly and Katie Ross, along with all our pipe and coupling manufacturers, for their tremendous support.

Testing Report

Link to testing report: /center/ciest/sites/default/files/2025-03/240820%20DW-Serrated%20vs%20Nonserrated__Final%20Draft_v2.pdf

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Performance Assessment of iPVC Pipe and Coupling for Large Ground Movement

Anonymous — Tue, 15 Nov 2022 07:00:00 +0000

Performance Assessment of iPVC Pipe and Coupling for Large Ground Movement Anonymous (not verified) Tue, 11/15/2022 - 00:00

Project Title: Performance Assessment of iPVC Pipe and Coupling for Large Ground Movement

Industry Partners: East Bay Municipal Utility District, Denver Water

CIEST Personnel: Nicholas Berty, Cory Ihnotic, Katherine O’Dell, Jessica Ramos

Primary Investigator: Prof. Brad Wham

Year: 2022

Project Summary: The intent of this study is to define the seismic response of iPVC pipeline systems with couplings and to illustrate procedures for interpreting laboratory results to seismically classify pipeline system performance following developing ASCE seismic guidelines. Twenty large-scale tests were performed on 6-in. diameter DR14 (PC305) iPVC pipe (C900) with five different commercially available reinforced connections. Test specimens were subjected to tension, compression, cyclic, and four point bending tests, determining the ultimate load capacity for each system in both axial and transverse directions. This study provides the first seismic classification for plastic pipe systems with reinforced connections.

Appreciation is extended to David Katzev and Katie Ross, along with all our pipe and coupling manufacturers, for their tremendous support.

Link to Report

The intent of this study is to define the seismic response of iPVC pipeline systems with couplings and to illustrate procedures for interpreting laboratory results to seismically classify pipeline system performance following developing ASCE seismic guidelines.

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Seismic Evaluation of Hazard-Resistant Lifelines: Fusible PVC Pipe and Fittings

Brad Wham — Sun, 18 Jul 2021 17:03:45 +0000

Seismic Evaluation of Hazard-Resistant Lifelines: Fusible PVC Pipe and Fittings Brad Wham Sun, 07/18/2021 - 11:03

Project Title: Seismic Evaluation of Hazard-Resistant Lifelines: Fusible PVC Pipe and Fittings

Industry Partners: Aegion Corportation - Underground Solutions Inc.

CIEST Personnel: Cory Ihnotic, Jessica Ramos, D.K Anderson, David Balcells

Primary Investigator: Prof. Brad Wham

Year: 2021

Project Summary: The intent of this study is to impose external loading conditions to test specimens that are representative of the significant deformations possible during earthquake-induced ground motions such as landsliding, fault rupture, and liquefaction-induced lateral spreading, characterizing the pipeline system capacity. This testing program seeks to define the seismic response of fusible PVC (fPVC) pipeline systems with both fused connections and external couplings, illustrating procedures and best practices for conducting full-scale tests and interpreting laboratory results. Thirteen large-scale tests were performed on 6-in. diameter DR18 (PC235) fusible PVC pipe (C900) with three different connection types. Test specimens were subjected to tension, compression, cyclic, and four point bending tests, determining the ultimate load capacity for each system in both axial and transverse directions.

Link to report: /center/ciest/sites/default/files/attached-files/240724_ciest-ugs_fusible_report_to_be_published.pdf

The intent of this study is to impose external loading conditions to test specimens that are representative of the significant deformations possible during earthquake-induced ground motions such as landsliding, fault rupture, and liquefaction-induced lateral spreading, characterizing the pipeline system capacity.

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Axial Capacity of Reinforced Gasketed Joints

Anonymous — Wed, 30 Sep 2020 06:00:00 +0000

Axial Capacity of Reinforced Gasketed Joints Anonymous (not verified) Wed, 09/30/2020 - 00:00

Full Project Title: Axial Capacity of C900 PVC Pipe with Reinforced Gasketed Joints

Year: 2019-20

Industry Partner: Denver Water

CIEST Personnel: Jessica Ramos, John Hindman, Brice Lucero, David Ballcells, Hayley Parnell, and Porter Hawkins

Primary Investigator: Prof. Brad Wham

Summary: The objective of this study was to impose externally applied axial loading to reinforced gasketed water pipeline joints to establish upper bound performance under worst case conditions of ground movement. Test protocols included axial tension and cyclic (progressive tension and compression) loading on bell-spigot style C900 PVC pipe to simulate deformations possible during natural hazards such as earthquakes and landslides . The test specimens consisted of either RieberLok Gasketed or Diamond Lok-21 pipe with a restraining ring. Tests provided measures of axial displacement capacity, pipeline connection strength, and failure mechanism. The results indicated these systems as potentially viable solutions for regions prone to persistent soil movement and settlement. Tests were conducted in partnership with Denver Water.

Failed specimen after testing in tension.

View the full report here.

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Tension Testing of Flexible Expansion Joints

Anonymous — Sun, 19 Jul 2020 18:26:52 +0000

Tension Testing of Flexible Expansion Joints Anonymous (not verified) Sun, 07/19/2020 - 12:26

Project Title: Tension Testing of Flexible Expansion Joints

Industry Partners: EBAA Iron, Inc.

CIEST Personnel: Hailey Parnell, Lindsay Guerrero, Bruce Lucero

Primary Investigator: Prof. Brad Wham

Year: 2020

Project Summary: The intent of the test program is to investigate the axial performance of a Flex-Tend Flexible Expansion Joint (FEJ) and a Force-Balanced FlexTend Flexible Expansion Joint (FBFEJ), each nominally 6-in. diameter. Externally applied axial tension load test results are compared to data obtained from internal pressure burst tests and demonstrate that, while similar levels of axial force are required to initiate component failure, the failure mechanisms differ and and influenced by the circumferential stress supplied during burst testing. The work was undertaken in the Center for Infrastructure, Energy, and Space Testing (CIEST) which is affiliated with the Civil, Environmental, and Architectural Engineering Department at the ��ý��.

Follow this link for the Report by H.L. Parnell, L. Guerrero, B.A. Lucero, and B.P. Wham.