evaluation study of nyloplast inline drain

FINAL DRAFT REPORT
EVALUATION STUDY OF NYLOPLAST-ADS
INLINE DRAIN AND DRAINAGE BASIN
RFQ#02-01(C09)
Contract No. 350A07-002
Submitted to
Nyloplast
and
The Pennsylvania Department of Transportation
Bureau of Municipal Services
Under the program for
New Product Evaluation for Low Volume Roads
Prepared by
Angelica M. Palomino, Ph.D.
Assistant Professor
Department of Civil and Environmental Engineering
The Pennsylvania State University
University Park, PA
Ph: (814) 865-9427
Fax: (814) 863-7304
Email: amp26@psu.edu
Pennsylvania Transportation Institute
The Pennsylvania State University
201 Transportation Research Building
University Park, PA 16802
July 31, 2007
Table of Contents
Table of Contents _______________________________________________________ 2
Background ___________________________________________________________ 3
Study Objectives and Approach____________________________________________ 3
Product Description _____________________________________________________ 4
Literature Review _______________________________________________________ 5
Approvals by other State DOTs _______________________________________________ 6
Site Visits _____________________________________________________________ 7
Accelerated Traffic Load Testing _________________________________________ 10
Background_______________________________________________________________ 10
Pennsylvania Transportation Institute (PTI) Test Track _________________________ 12
Experimental Procedures ___________________________________________________ 12
Results and Analysis _______________________________________________________ 17
Accelerated Pavement Testing______________________________________________________ 17
Seasonal Observations ____________________________________________________________ 17
Previous Testing - Utah State University: Structural Performance__________________________ 18
Summary and Recommendations _________________________________________ 19
References ___________________________________________________________ 20
APPENDIX A_________________________________________________________ 21
15-inch and 24-inch Drainage Basin CAD Drawings _____________________________ 21
Background
Maintenance costs and service life are critical issues for drainage structures.
The
adoption of PVC-bodied alternatives to the traditional concretes-based structures is on the
rise among various state departments of transportation nationwide. In other states, those
products have proven to be a competitive alternative both in cost and in ease of
installation.
This study is an evaluation of PVC inline drains and drain basins to be evaluated for
potential use in low-volume roads. These drainage structures are produced by Nyloplast,
a division of Advanced Drainage Systems (ADS) in Ohio. Based on the results of this
evaluation study, The Pennsylvania Department of Transportation (PennDOT) Bureau of
Municipal Services will ultimately approve/disapprove the listing of Nyloplast-ADS
Storm Drainage Structures in Publication 447, which allows liquid-fuel monies to be used
by municipalities for purchasing, contracting, and incorporating the approved products.
Study Objectives and Approach
The purpose of this study is to evaluate the performance of the Nyloplast Inline Drain and
Drain Basin surface drainage structures for use in lower volume local roadways and nontraffic/unpaved areas and to determine the products’ suitability for inclusion in
PennDOT’s Publication 447. The specific objectives to be achieved are:
1. Evaluate the Nyloplast Inline Drain and Drain Basin with regard to: product
performance, durability, cost-effectiveness, and ease and safety of installation;
2. Review and modify, if necessary, existing specifications and guidelines for using
Nyloplast Inline Drains and Drain Basins;
3. Provide, upon findings from the above tasks, recommendation to PennDOT Bureau of
Municipal Services regarding the inclusion of the products in Publication 447.
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Product Description
General Product Names: Surface Drainage Structures
•
Trade Name: Nyloplast Drain Basin
Drain Basin Model: 28**AG**X – The first set of ** refers to the drain basin
diameter, and the second set of “**” refers to the number of stubs. The “X”
requires input from the user as to the type of pipe connecting to the basin, i.e.
ADS N-12 pipe, PVC SDR 35, etc.
Proposed Specific Use in the Transportation System: To catch storm water
surface runoff and discharge into a storm sewer. The drain basin is designed
for use in both traffic/paved areas and in non-traffic/unpaved areas. It may be
installed in both flexible and rigid pavements.
•
Trade Name: Nyloplast Inline Drain
Inline Drain Model: 27**AG**X – The first set of ** refers to the inlet drain
diameter, and the second set of “**” refers to the riser pipe diameter. The “X”
requires input from the user as to the type of riser pipe, i.e. ADS N-12 pipe,
PVC SDR 35, etc.
Proposed Specific Use in the Transportation System: To catch storm water
runoff and discharge into a storm sewer.
Inline drains is intended to be
installed on top of a riser pipe that connects to the storm sewer system via a tee
in the middle of a pipe run or a 90° bend at the end of a pipe run. The inline
drain is designed for use in both traffic/paved and non-traffic/unpaved areas,
and in both flexible and rigid pavement systems.
In-line Drain/Drain Basin. The Nyloplast drainage structure bodies are made from
PVC.
Each structure is thermo-molded from PVC pipe stock to the specified
configuration. Drainage pipe connection stubs are also manufactured and thermo-molded
from PVC and are formed such that a water-tight connection is maintained with the pipe
system. In-line drains may be obtained in diameter sizes 8”, 10”, 12”, 15”, 18”, 24”, and
30”, and adapt to pipe sizes 4” through 30”. Drain basins are available in diameter sizes
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8”, 10”, 12”, 15”, 18”, 24”, and 30”. Drain basin adapters are available in sizes 4”
through 8”. Drain basins may be formed to accommodate changes in elevation, inlet and
outlet pipe diameter, inlet and outlet pipe type, and direction.
Joints and Connections. The pipe bell spigot is joined to the main body of the drain
basin. Pipe stubs, formed from the same stock PVS as the drainage structure bodies, and
ASTM F477 rubber gaskets are provided by Nyloplast for assembling a water-tight
connection to the riser pipe. The joints are designed to conform to tightness standards
described in ASTM 3212 Standard Specification for Joints for Drain and Sewer Plastic
Pipes Using Flexible Elastomeric Seals.
Grates/Covers. Grates are manufactured from ductile iron and provided by Nyloplast.
Grates are made specifically for each fitting to provide a round bottom flange that closely
matches the surface drainage inlet diameter. Types of grates/covers available include a
standard grate, solid cover and a domed grate. Available sizes (diameters) are 10”, 12”,
15”, 18” and 24”. All grates/covers are made from ductile iron conforming to ASTM
A536 Grade 70-50-05, except for the 12” and 15” grates/covers which have a cast-iron
frame (A48-Class 30B). Grates/covers are furnished with a black paint.
Literature Review
PennDOT bulletins, publications for approved products, and specifications reviewed for
this study are listed below along with the proposed section for inclusion of the evaluated
products:
•
Publications 447: Approved Products for Lower Volume Local Roads: Section 600,
Suppliers and Manufactures, Drainage Systems and Drainage Related Items
•
Bulletin 15: Approved Construction Materials (Publication 35): Section 600: An
Alternative to Drainage Systems and Drainage Related Items (Section 605.2(a), note
K)
•
Publication 408: General Specification: Alternative to section 605, Endwall, Inlets,
Manholes, and Spring Boxes; Drainage Systems.
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Approvals by other State DOTs
Nyloplast drainage basins and in-line drain products have been approved for use in
pedestrian (non-traffic) and/or low-volume traffic roads by a number of other state
departments of transportation. Table 1 lists states and approval conditions for Nyloplast
drainage basins and in-line drains.
Table 1. State DOTs Approving Use of Nyloplast Products
State
Florida
Georgia
Approved July 2000
Ohio
New York
North Carolina
Tennessee, Maintenance
Division
Virginia
Approved April 2006
Washington State
Approved April 2005
Wisconsin
Approved February 2004,
Valid until February 2009
Approval/Conditions
Back of sidewalk drain, Index #282
Approved as an alternate under Georgia DOT Standard
1035 for use on construction and maintenance projects with
the condition that they can only be used as yard drains or
pedestrian walkway drains behind the curb and gutter and
out of automobile traffic areas.
Standard detail CB-7 and I-1
---Approved for use on routes with an average daily traffic
volume of < 4000 vehicles per day
Can only be used on roads where the average daily traffic
(ADT) is less than 20,000 in both directions (10,000 in one
direction) where normal highway loadings do not occur. As
with other approved inlets, it should never be placed directly
in a frequently traveled wheel path as per Section 5-5 of the
Washington State Hydraulics Manual. It must also be no
more than 5 feet from the invert of the bottom of the basin
to the top of the grate and must be able to handle H-25 type
wheel loading.
Approved as an alternate to s. Comm 82.35 based on the
Wisconsin Statutes and the Wisconsin Administrative Code.
This product must be installed in accordance with the
manufacturer's printed instructions, system approval, plan
approval, and Wis. Adm. Code. If there is a conflict
between the manufacturer's instructions and the plan
approval, system approval or Wis. Adm. Code, the Wis.
Adm. Code, plan approval and system approval will take
precedence.
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Site Visits
Three installation sites, two school facilities and one subdivision, were visited in
Hershey, PA, in September 2006. The sites, listed in Table 2, represent examples of both
in-line drains and drain basins at various stages of installation and for a range of storm
water runoff loading conditions.
Table 2. Nyloplast product installation site visits completed September 2006
Site
•
Milton Hershey Old Senior
Hall
Hershey, PA
•
•
•
Villages at Springbrook
Farms
Campbelltown, PA
•
•
•
Hershey High School
Hershey, PA
•
•
Nyloplast Product(s)
Nyloplast Drain Basins in
yard, parking adjacent to
building
Size range 12” diameter
to 24” diameter – shallow
and deep burial
Mixture of solid and
Standard H-25 Grates
Nyloplast Drain Basins in
Rain Gardens, Infiltration
Beds, Parallel Beds
Size Range 12” diameter
to 24” diameter
Mixture of Domed,
Pedestrian, Drop-in, Solid
and H-25 Grates
Nyloplast Drain Basins in
courtyard and parking
area behind building
expansion
Size Range 8” (Roof
Drains) to 18” Yard
Drains – Deep Burial
8” Solid Drop-in Lids and
18” Pedestrian Grates
Notes
Handwerk Contracting
Hummelstown, PA
•
•
At the time of visit:
Phases 1, 3, and 7
complete or ongoing;
phases 2, 4, 5, 6, 8 to
be completed in future
Abel Construction,
Mountville, PA
JBL Excavating
Hershey, PA
Figure 1 shows samples of the Nyloplast products after delivery to the construction site
(Old Senior Hall), but prior to installation. Each drainage structure body is individually
labeled (Figure 2) to identify the delivery recipient – in this case the contractor – the
structure dimensions, pipe stub sizes and locations, and the installation instructions.
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Drain structure heights can be easily modified in place after installation to match
surrounding grade, such as the case shown in Figure 3-a (Hershey High School – future
parking lot). Excavation site and installation of an inline drain at the same site is shown
in Figure 3-b.
(b)
(a)
(c)
Figure 1. Drainage structure specimens prior to installation at Old Senior Hall (school
facility), Hershey, PA: (a) drain basin, (b) ductile iron grates, and (c) pipe stub
with connection gasket.
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Figure 2. Drainage structure body label. Each piece is shipped with a customized label
noting the contractor (installer), the structure dimensions, pipe stub sizes and
locations, and the installation instructions.
(a)
(b)
Figure 3. Drainage structures at Hershey High School, Hershey, PA: (a) newly installed
drainage basin and (b) installation of drainage basin.
Previously-installed drainage structure specimens were also inspected in a Hershey, PA
subdivision (Villages at Springbrook). The oldest homes within the subdivision were less
than five years old at the time of the visit, and the neighborhood was in various stages of
construction, including undeveloped fields. Figure 4 shows one example of an observed
Nyloplast drainage basin with a weir and dome grate. The grate was removed to inspect
the drainage performance (the area experienced rainy conditions the day prior to
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inspection).
As can be seen from the figure, the basin appears to be in excellent
condition, with no clogging or other obstructions to flow.
(a)
(b)
Figure 4. Drainage structures at new subdivision, Hershey, PA: (a) previously installed
drain basin with dome grate and (b) drain basin interior with weir.
Accelerated Traffic Load Testing
Background
The purpose of the accelerated load testing is to evaluate the long term performance and
durability of the product in a short time period by applying accelerated loading cycles.
This is done by using the MMLS, Model Mobile Load Simulator (shown in Figure 5),
which applies a third of the actual 18 kip load per wheel pass, but maintains the same tire
pressure that is typically applied on roadway pavements. The MMLS traffic speed varies,
but is typically set at two wheel applications per second. At such speeds, the performance
of the product can be assessed very quickly.
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CRANK FOR HEIGHT SETTING
363
Φ300 PNEUMATIC TYRE
900
Φ300
HOT
DRIVE MOTOR
WATER
INLET
SUCTION
OUTLET
80
1260
2360
LONGITUDINAL SECTION
CROSS SECTION
(a)
(b)
Figure 5. (a) Schematic diagram of MMLS3 and (b) side view of MMLS3.
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PONDED
WATER
Figure 6. Aerial view of the PTI test track in State College, PA.
Testing utilizing the MMLS3 took place under the supervision of Dr. Ghassan Chehab,
assistant professor, Department of Civil and Environmental Engineering, Penn State.
Pennsylvania Transportation Institute (PTI) Test Track
The test track (aerial view shown in Figure 6) is a one-mile oval loop built in the 1980s.
Since its construction, the track has been rehabilitated to accommodate a number of
transportation and pavement research studies. The accelerated test location for the drain
basins, marked by the large star in the lower right corner of Figure 6, was carefully
selected such that the applied traffic loading could be strictly controlled and monitored.
The location also provides easy access to the installed product samples for monitoring
with time.
Experimental Procedures
The two drainage products were installed by Stone Valley Construction (Pine Grove
Mills, PA) according to Nyloplast specifications and under the supervision of Nyloplast
representatives and the PI at the PTI test track. The products chosen for this study are the
15-inch Drain Basin (2815AG__X) and the 24-inch Drain Basin (2824AG__X) (CAD
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drawings are provided in Appendix A). These products were selected to represent a
range of product sizes and use. Figures 7 and 8 highlight the installation process of the
two Nyloplast products at the test track. Installation took place 19September2006 over a
period of less than five hours. The installed systems are shown in Figure 9, just after the
concrete collar was poured and after the concrete was allowed to cure for 50 days.
Accelerated testing using the MMLS3 took place 09November 2006, approximately 50
days after installation of the drain basin systems to allow the concrete layer to cure.
Figure 10 shows the MMLS3 placed on the 24” basin grate at the beginning of the test.
A total of 100,000 cycles were applied to each basin surface, i.e. on top of the grate.
Each cycle consists of four wheel passes, and two wheel passes equate to two axels (or
one vehicle pass). The number of applied cycles is based on the estimated number of
passes for a low-volume road for 1 to 2 years. Cycle application took approximately 13
hours per basin to complete.
The basin systems were also observed over four seasons (summer 2006 to spring 2007) to
investigate their response to typical environmental factors experienced in Pennsylvania.
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Excavation of basin locations
Pit dimensions: 5ft×5ft×4ft deep
Compaction of base aggregate layer
Placement and leveling of 24” basin
Compaction of first supporting lift of
aggregate layer
Density measurement of first aggregate
lift using nuclear density gauge
Figure 7. Basin installation: pit excavation and surrounding aggregate layer
compaction for 24” drain basin.
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Density measurement of last lift
Wooden frame for concrete placement
24” basin with grate in place
15” basin with grate in place
Concrete poured over aggregate layer
Surface smoothing of concrete layer
Figure 8. Basin installation: basins with 2A aggregate layer and pouring of concrete
layer.
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Figure 9. Basins with freshly-poured concrete layer (a) 15” basin (b) 24” basin, and
basin systems 50 days after installation (c) 15” basin and (d) 24” basin. A rim
of asphalt concrete was placed to fill the gap between the Portland cement
concrete and the surrounding pavement.
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Figure 10. MMLS3 on 24” basin just prior to accelerated testing.
Results and Analysis
Accelerated Pavement Testing
The tested basins after application of simulated traffic cycles are shown in Figure 11.
After 100,000 cycles, both basins remained intact and in excellent condition. While tire
markings from the MMLS3 wheels were evident along the trafficking path, no signs of
significant wear were observed of the grate, the concrete and the basin itself. All system
components and connections remained undamaged.
Seasonal Observations
The drainage basins were observed over four seasons: summer, winter, fall and spring
(summer 2006 through spring 2007). The temperature during the observation period
ranged from -2°F to 95°F. Weather conditions over the observation period included
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(b)
(a)
Figure 11. Basin systems after application of 100,000 trafficking cycles: (a) 15” basin
and (b) 24” basin.
heavy rains and snowfall. The basins did not show any signs of temperature or weatherrelated damage at the end of the observation period.
Previous Testing - Utah State University: Structural Performance
Drain basins of diameters 18”, 24” and 30” were installed in a test field and subjected to
extreme loading conditions to evaluate basin response to worst-case scenario conditions.
A 20-kip eccentric (offset) load was applied to each basin system such that the stress at
the approach edge was doubled. The basin systems resisted the applied load. However,
the investigator noted that the concrete collar carries much of the load. If the concrete
collar becomes recessed, the stresses experienced by the 18”, 24” and 30” basins are 2000
psi, 1200 psi and 800 psi, respectively. The basins fail plastically with no cracking.
While this scenario is unlikely, the yield strength of PVC is greater than 5000 psi.
Hence, the basins will probably not fail as traffic loads are less concentrated. For further
testing details see the “Test Data” section of the New Product Evaluation application
submitted to PennDOT by Nyloplast (March 2005).
A second structural performance test was performed on two specimens of the 24-inch
drain basin under simulated wheel loads (Moser and Folkman, 2004). It was found that
the concrete rings failed before the basins, at an applied load of 104,000 and 104,600
pounds, respectively.
The basins remained intact without deforming or cracking
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throughout most of the loading phase, up to 94,200 lbs. This load corresponds to the
point at which the concrete collar showed signs of cracking.
Summary and Recommendations
This study incorporates a review of related PennDOT specifications, approvals from
other state DOTs, structural performance studies performed by Utah State University
testing laboratories, and accelerated testing performed by Penn State University to
evaluate Nyloplast inline drains and drainage basins. Significant findings include:
•
The evaluated products are compliant with Specification 408, Section 605 (Standard
Drawing RC 34
•
The evaluated inline drains and drainage systems are suitable for use as an alternative
to approved surface drainage structures and storm drain inlets
•
Installation of proposed drainage products is relatively simple, can be completed in a
few hours (quick installation), and repeatable for a wide variety of locations. All
necessary components and connections are designed for ease of installation and
adaptability to each individual pipe system.
•
When installed according to the manufacturer’s specifications, the loading capacity of
the drainage system meets the H-25 rating. Testing of structural capacity revealed that
the PVC bodies, overlain by a concrete collar, can withstand loads up to ~94,000
without signs of cracking or deformation.
•
Based on accelerated testing, when installed according to the manufacturer’s
specifications, the drainage systems easily withstand simulated low-volume traffic
loads.
•
At the time of this study, the evaluated drainage products have been approved by a
number of other DOTs for their use in conditions ranging from pedestrian-only
locations to local or low-volume traffic load conditions.
Based on these findings, the investigator recommends that the proposed Nyloplast inline
drains, drain basins, and accompanying inlet grates and covers be added to PennDOT
Publication 447 Approved Products for Lower Volume Local Roads, Section 600, with
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the condition that installation comply with guidelines set in PennDOT Publication 408
Construction Specifications, proposed alternative to section 605.
References
Moser, A.P. and Folkman, S.L. (2004), “Structural Performance of 24-inch Drain Basins
Under Simulated Wheel Loads”, Test Report, Buried Structures Laboratory, Utah State
University.
Nyloplast New Product Evaluation Submittal, “Surface Drainage Structures”, submitted
to Pennsylvania Department of Transportation, December 2004.
Nyloplast New Product Evaluation Submittal, “Surface Drainage Structures Drain
Basin”, submitted to Pennsylvania Department of Transportation, March 2005.
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APPENDIX A
15-inch and 24-inch Drainage Basin CAD Drawings
21