Servlifeeval PDF
Servlifeeval PDF
P R E PA R E D
F O R
N A T I O N A L
C O R R U G A T E D
S T E E L
2 0 0 2
P I P E
A S S O C I A T I O N
M A R C H
EVALUATION PROCEDURES
Fifteen of the 17 sites were selected for evaluation. Sites 15 and 20 are sand filter systems and were not evaluated because access to the invert would require removal of sand filter media. During the field inspection it was found that one of the systems (Site No. 12) had been removed during redevelopment. In addition, it was not possible to gain access to two of the systems, sites 1 and 18. Thus testing was per-
Rating
10095 90 8085 75 6055 50 4540 3530 25 2015 105 0
Description
galvanizing intact galvanizing partly gone, some rust galvanizing gone, significant metal loss
80
60
40
20
0 1 2 3 5 6 7 8 9 12 13 14 15 16 17 18 20 21
Site #
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Condition Survey of Corrugated Steel Pipe Detention Systems, NCSPA, Washington, DC, March 1999. Condition and Corrosion Survey: Soil Side Durability of CSP, Corrpro Companies, March 1991.
Table 1. Stormwater Detention System Overview Site No. 2 3 5 6 7 8 9 13 14 16 17 21 Location Industrial, Montgomery County, MD Industrial, Montgomery County, MD Industrial, Montgomery County, MD Commercial, Montgomery County, MD Commercial, Montgomery County, MD Commercial, Montgomery County, MD Commercial, Montgomery County, MD Commercial, Montgomery County, MD Residential, Fairfax County, VA Residential, Fairfax City, VA Residential, Fairfax City, VA Residential, Alexandria, VA
Coating Galvanized Galvanized Galvanized Galvanized Galvanized Fully Bituminous Coated Galvanized Aluminum Coated Type 2 Fully Bituminous Coated Aluminum Coated Type 2 Fully Bituminous Coated Galvanized
Corrugation 1x3" Helical 1x5" Helical 1x5" Helical 1x5" Helical 1x5" Helical 1x5" Helical 1x5" Helical 1x5" Helical 1x5" Helical 1x5" Helical 1x5" Helical 1x5" Helical
Pipe Soil Depth Age to Top of (years) Pipe (feet) 26 26 21 21 21 21 21 11 6 11 6 6 2 4.25 4 4 2 2.5 13 6 6 11 12 6
formed on 12 sites. Table 1 presents an overview of each site including the numbering, location, land use, system size, age, and sampling performed at each of the sites.
coupons (112 inch in diameter) were obtained from the top and invert at each location for subsequent determination of the remaining zinc layer thickness. A total of 25 coupons were collected. Soil and water samples were also collected from each site for laboratory analysis. Wherever possible, photographic documentation of the detention systems was made.
Laboratory Work Samples collected from the field testing were evaluated in the laboratory. Corrugated steel pipe coupons were polished metallographically along their thickness to reveal the zinc layer. The zinc layer thickness was measured at ten locations with the help of a low-powered optical microscope and an average thickness was calculated. Soil samples were
Field Testing Field-testing consisted of performing visual observations, in-situ measurements of soil resistivity, soil pH, and redox potential at each site. Disk
Table 2. Field Test Data Site No. Location Galvanized Systems 2 Industrial, Montgomery County, MD 3 Industrial, Montgomery County, MD 5 Industrial, Montgomery County, MD 6 Commercial, Montgomery County, MD 7 Commercial, Montgomery County, MD 9 Commercial, Montgomery County, MD 21 Residential, Alexandria, VA Fully Bituminous Coated Systems 8 Commercial, Montgomery County, MD 14 Residential, Fairfax County, VA 17 Residential, Fairfax City, VA Aluminum Coated Type 2 Systems 13 Commercial, Montgomery County, MD 16 Residential, Fairfax City, VA *Soil resistivity determined with a Collins Rod **CSE = copper sulfate electrode NM - Not Measured Soil Resistivity* Bottom Top 4000 4000 6500 13000 20000 50000 NM 20000 11000 15000 10000 NM 7000 4000 11000 6000 3300 NM 1900 2000 7100 6000 5500 28000 Potential, mV vs. CSE** Bottom Top Surface -681 -562 -644 -786 -741 -641 -629 -938 -973 -926 -664 -617 -637 -620 -694 -740 -546 -690 -706 -721 -481 -946 -672 -665 -508 -549 -633 -689 -722 -724 -671 -946 -955 -933 -425 -613 pH Bottom 6.85 NM NM 6.85 7.24 NM 6.27 NM 7.14 7.16 10.4 7.81 Top 6.74 NM 8.14 6.83 7.86 7.38 6.49 NM 8.67 6.8 10.1 8.01
evaluated to identify the soil type and physical characteristics, determine resistivity, pH, moisture content, chlorides and sulfides. Water samples were evaluated to determine pH, resistivity, chlorides, and sulfides. Utilizing the soil and water analysis data, the predicted service life of the detention system was calculated using a variety of methods:
FINDINGS
Field Tests Table 2 summarizes the results of the soil resistivity, pH and potential measurements made at each site. Over 80% of the potential readings were found to be in the range of 617 mV to 946 mV with respect to a copper-copper sulfate electrode. Potential readings in this range indicate that the galvanized layer has not corroded away and exposed the bare steel.
calculate the remaining life of the galvanized layer using the software program previously developed by Corrpro for NCSPA2. That study of culvert and storm sewer installations concluded indicated that 93.2% of the plain galvanized installations have a soil side service life in excess of 75 years, while 81.5% have a soil side service life in excess of 100 years. The software generates service life predictions from a statistical model developed to accurately pre-
Table 3. Laboratory Soil Analysis Data and Soil Side Life Prediction* Sample Moisture Site No. Location Soil Type Sample Color (%) pH Galvanized Systems 2 Top sandy clay gray 23.72 7.4 Invert loam gray-brown 27.32 7.7 3 Top clay gray 29.14 7.9 5 Top silty loam gray-brown 23.83 7.9 Invert clay gray-brown 26.51 7.4 6 Top silty clay light red brown 27.52 6.4 Invert silty clay light red brown 29.18 6.8 7 Top silty clay loam light red brown 23.67 6.3 Invert silty clay loam light red brown 30.21 6.6 9 Invert clay gray-red brown 34.00 7.6 21 Top silty clay light red gray 24.17 6.0 Fully Bituminous Coated Systems 8 Top silty clay loam yellow gray 25.58 7.7 Invert silty clay loam yellow gray 27.48 7.6 14 Side silty clay loam light gray brown 23.07 5.7 Invert caliche light gray brown 32.38 6.6 17 Invert silty clay light red brown 27.95 5.1 Aluminum Coated Type 2 Systems 13 Side silty clay light red brown 26.73 6.6 Invert silty clay light red brown 34.33 7.2 16 Top silty loam light gray brown 20.40 4.9
Chloride (ppm) 16 60 32 20 27 37 28 42 9 10 34 32 30 10 10 12 30 18 16
Sulfide Resistivity 16 gage galvanized Gage Predicted (ppm) (ohm-cm) pipe life (yrs)* Multiplier Pipe Life 0.3 0 0 0 0 0 0.3 0 0 0 0 0 0 0 0 0 0 0 0 722 1684 2538 8696 3663 4630 5051 2941 11765 2899 1992 2899 3846 7813 10417 6993 1961 3745 10417 91.5 70.9 100.11.0 141.4 91.7 57.4 67.7 50.4 122.9 139.7 45.4 94.9 96.8 79.9 115.9 59.3 60.6 100.1 54.0 1.0 1.0 1.0 1.3 1.3 1.3 1.3 1.3 1.3 2.3 1.8 1.3 1.3 1.8 1.8 1.8 2.3 2.3 1.3 91.5 70.9 100.1 183.8 119.2 74.6 88.0 65.5 159.8 321.3 81.7 123.4 125.8 143.8 208.6 106.7 139.4 230.2 70.2
*Service life for 16 gage galvanized pipe using software previously developed by Corrpro Companies, Inc for NCSPA
dict service life of galvanized CSP for sites where durability is limited by soil side corrosion. The model predicts the condition of the protective galvanized coating over time plus the life of 16 gage black steel. According to the author:
When the galvanized coating reaches the point that pitting of the steel substrate could begin, the model uses black steel corrosion data from 23,000 black steel underground storage tank sites to analyze overall durability vs. time. The black steel used in the
model was 16 gage. Therefore the model does not accommodate added life projections due to the increased thickness of the pipe wall. Use of this data induces significant conservatism also, because, it is based on steel not previously galvanized, and there-
Table 4. Service Life Predictions in Accordance with the California Method and AISI Method Sample Resistivity California AISI Pred. Site No. Location pH (ohm-cm) Gage Pred. Life (yrs) Life (yrs) Galvanized Systems 2 Crown Soil 7.4 722 16 28 57 Invert Soil 7.7 1684 40 80 Water* 5.5 613 5 10 3 Crown Soil 7.9 2538 16 48 95 Water** 7.5 881 31 62 5 Crown Soil 7.9 8696 14 97 205 Invert Soil 7.4 3663 68 144 Water 7.4 692 34 73 6 Crown Soil 6.4 4630 14 33 69 Invert Soil 6.8 5051 39 82 Water 6.2 5181 32 67 7 Crown Soil 6.3 2941 14 27 58 Invert Soil 6.6 11765 44 93 Water 7.3 3165 55 116 9 Invert Soil 7.6 2899 10 108 231 Water 7.9 2066 94 201 21 Crown Soil 6.0 1992 12 29 61 Water 6.2 8333 50 106 Fully Bituminous Coated Systems 8 Crown Soil 7.7 2899 14 62 130 Invert Soil 7.6 3846 69 147 Water 7.6 3135 64 135 14 Side Soil 5.7 7813 12 44 94 Invert Soil 6.6 10417 59 125 Water 6.9 4184 54 114 17 Invert Soil 5.1 6993 12 38 80 Water 6.6 12195 61 130 Aluminum Coated Type 2 Systems 13 Side Soil 6.6 1961 10 47 100 Invert Soil 7.2 3745 84 179 Water 7.3 4016 100 214 16 Crown Soil 4.9 10417 14 30 64 Water 6.8 5814 40 85
Minimum California
Minimum AISI 57
28 31 34 62 73
32
67
27
58
94 29
201 61
62
130
44
94
38
80
47
100
30
64
Notes: 1. The above resistivity and pH data was obtained from laboratory analysis of field samples. 2. All predictions are for galvanized pipe of the designated gage. No multiplier or "add-on" for additional coating has been used *This water smelled of antifreeze. It was considered an aberrant condition for service life prediction. **This "water" was saturated organic matter.
fore, does not recognize the effects of residual galvanizing and the alloy layer formed during the galvanizing in slowing the corrosion process. Additionally, the slowing of the corrosion pitting rate with time for thicker gages cannot be accommodated. However, these shortcomings add conservatism to the service life estimates. The calculations show the average predicted life of a 16 gage galvanized pipe in these environments is about 86 years. Table 3 also attempts to adjust the service life prediction by using a gage multiplier as recommended by the AISI Method. This shows that the average predicted life of the systems is about 130
years. The minimum predicted service life for any of the systems is 65 years. Taking all of the above factors into consideration, the total service life of the structures would be in excess of 100 years. Table 4 shows the predicted service life of each detention system using both the California and AISI methods. The California Method was developed by Stratful to predict time to fist perforation, which is not considered the end of service life. The AISI Method (also developed by Stratful) is based on the Caltrans Method but is used to predict average invert service life.3 For each method, the service life was calculated using each of the environmental samples (soil and
water). The minimum of the calculated values for each pipe is then identified in the table. Notice that systems 2, 3, and 7 are very near the end of the California Method predicted service life (first perforation). Yet the systems are all in quite good condition, with most of the galvanized coating still in tact. There would certainly need to be extreme corrosion to occur if they are to have penetrations at the age predicted by the California Method. This suggests that the AISI Method provides a more accurate service life prediction than the California Method for detention systems, however both methods provide very conservative predictions for these environments.
y = 2.8093x 2 R = -2.3409
y = 4.5769x 2 R = 0.128
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100%
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Durability of CSP, Richard Stratful, Corrosion Engineering, Inc., 1986. Durability of Special Coatings for Corrugated Steel Pipe, J.C. Potter, I Lewandowski, and D.W. White, Federal Highway Administration, Report No. FHWA-FLP-91-006, June 1991.
Table 5. Service Life Analysis Using the Technique Developed by Potter Thickness (inches) Percent Min. Calif. Site No. Original (est) Min Perforation Pred. Years* Galvanized Systems 2 0.058 0.048 17.2% 28 3 0.058 0.056 3.4% 31 5 0.072 0.069 4.2% 34 6 0.071 0.044 38.0% 32 7 0.071 0.068 4.2% 27 9 0.128 0.126 1.6% 94 21 0.099 0.097 2.0% 29 Fully Bituminous Coated Systems 8 0.075 0.071 5.3% 62 14 0.098 0.096 2.0% 44 17 0.105 0.099 5.7% 38 Aluminum Coated Type 2 Systems 13 0.124 0.120 3.2% 47 16 0.070 0.053 24.3% 30
*Data from Table 4 of this report
Actual Age Percent of Years Calif. Pred. 26 26 21 21 21 21 6 21 6 6 11 11 92.9% 83.9% 61.8% 65.6% 77.8% 22.3% 20.7% 33.9% 13.6% 15.8% 23.4% 36.7%
To better understand the relationship between the California Method predictions and existing conditions, Potter correlated percent penetration with percent of California predicted service life expended.4 While there has been extensive debate over the validity of the technique, it is used as another method to compare service life predictions. Table 5 presents the minimum thickness measured on coupons from each system. That value is compared with the original thickness. The original thickness was determined in most cases by measuring overall thickness on the
crown of the pipe where the galvanizing was metallographically determined to be in-tact at nominally the original thickness. System 6 was the only system where an original thickness was difficult to determine, but a sufficiently conservative estimate was made based on measurements of the coupons. Figure 2 shows the data plotted in a manner similar to that used by Potter. Best-fit lines were regressed through all of the data for galvanized and asphalt coated pipes. No plot was made for aluminum coated pipes due to a lack of sufficient number of data points.
Using all data points, the analysis suggests that the galvanized systems are performing 2.8 times as well as the California Method would predict while the fully bituminous coated systems are performing 4.6 times as well as the California Method would predict for galvanized material. It should be noted that this multiplier increases to 7.3 times for galvanized systems if Site #6 is ignored. The inspection of the systems support the conclusion that the galvanized detention systems will last more than twice as long as the California Method might predict.
CONCLUSIONS
1. Corrugated steel pipe storm detention Systems (galvanized, aluminized, or bituminous coated) are performing satisfactorily in service. 4. The AISI Method appears more realistic in terms of predicting Detention System Service Life than the California Method, though both will provide conservative service life predictions for most 2. The service life of detention systems appears to environments. be driven by soil-side corrosion. 5. Visual observations and measurements of 3. There is no significant water-side invert deterioremaining galvanized layer thickness on ration. As a result, it is expected that the service coupons are in concurrence with theoretical callife would be longer for detention systems than culations using previously developed software for culverts or storm sewers. This may be due in for remaining life prediction. part to an absence of abrasion in the invert of limiting factor. detention systems. excess of 100 years where corrosion is the life practically any environment that will last in make it possible to design a detentions system in range of coatings and material thicknesses that 7. Corrugated steel pipe manufacturers provide a 100 years. 6. Physical inspection of these systems along with the analytical approach presented herein support the prediction of a functional service life for these galvanized detention systems in excess of
Water Data pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm Soil Data Moisture % pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm General Information Age of Inspection: Coating Type: Diameter: Corrugation: Land Use: Location: 23.72 7.4 16 0.3 722
5.5 139 0 613 27.32% 7.7 60 0 1,684 26 years galvanized 48" 1x5" helical industrial
Water Data pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm Soil Data Moisture % pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm General Information Age of Inspection: Coating Type: Diameter: Corrugation: Land Use: Location:
7.5 66 0.3 881 29.14% 7.9 32 0 2,538 26 years galvanized 48" 1x5" helical industrial
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Water Data pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm Soil Data Moisture % pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm General Information Age of Inspection: Coating Type: Diameter: Corrugation: Land Use: Location: 23.83 7.4 20 0 8,696
7.4 193 0 692 26.51% 7.4 27 0 3,663 21 years galvanized 60" 1x5" helical industrial
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Water Data pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm Soil Data Moisture % pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm General Information Age of Inspection: Coating Type: Diameter: Corrugation: Land Use: Location: 27.52% 6.4 37 0 4,630
6.2 16 0 5,181 29.18% 6.8 28 0.3 5,051 21 years galvanized 96" 1x5" helical commercial
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Water Data pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm Soil Data Moisture % pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm General Information Age of Inspection: Coating Type: Diameter: Corrugation: Land Use: Location: 23.67 6.3 42 0 2,941
7.3 14 0 3,165 30.21% 6.6 9 0 11,765 21 years galvanized 96" 1x5" helical commercial
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Water Data pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm Soil Data Moisture % pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm 25.58 7.7 32 0 2,899
General Information Age of Inspection: 21 years Coating Type: fully bituminous coated Diameter: Corrugation: Land Use: Location: 72" 1x5" helical industrial Montgomery County, Md.
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Water Data pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm Soil Data Moisture % pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm General Information Age of Inspection: Coating Type: Diameter: Corrugation: Land Use: Location:
7.9 34 0 2,066 34.00% 7.6 10 0 2,899 21 years galvanized 108" 1x5" helical commercial
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Water Data pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm Soil Data Moisture % pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm 26.73 6.6 30 0 1,961
General Information Age of Inspection: 11 years Coating Type: aluminum coated type 2 Diameter: Corrugation: Land Use: Location: 108" 1x5" helical commercial Montgomery County, Md.
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Water Data pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm Soil Data Moisture % pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm 23.07 5.7 10 0 7,813
General Information Age of Inspection: 6 years Coating Type: fully bituminous coated Diameter: Corrugation: Land Use: Location: 67"x104" 1x5" helical residential Fairfax City, Va.
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Water Data pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm Soil Data Moisture % pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm
General Information Age of Inspection: 11 years Coating Type: aluminum coated type 2 Diameter: Corrugation: Land Use: Location: 80" 1x5" helical residential (SFH) Fairfax City, Va.
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Water Data pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm Soil Data Moisture % pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm
General Information Age of Inspection: 6 years Coating Type: fully bituminous coated Diameter: Corrugation: Land Use: Location: 65"x107" 1x5" helical residential Fairfax City, Va.
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Water Data pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm Soil Data Moisture % pH Chloride, ppm Sulfide, ppm Resistivity, ohm-cm General Information Age of Inspection: Coating Type: Diameter: Corrugation: Land Use: Location:
6.2 120 0 8,333 24.17% 6.0 34 0 1,992 6 years galvanized 72" 1x5" helical residential Alexandria, Va.
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