Plastic Pipes Conference Association # 2023 Lake Buena Vista
Michael Pluimer, PhD, Joseph Babcanec, PE
While corrugated HDPE pipes are still the dominant plastic pipe product in the United States for culvert and storm sewer applications, Corrugated polypropylene pipes have continued to gain market share over the past decade. There are currently several different ASTM and AASHTO standards for these products, including ASTM F2764 (Standard Specification for 6 to 60 in. [150 to 1500 mm] Polypropylene [PP] Corrugated Double and Triple Wall Pipe and Fittings for Non-Pressure Sanitary Sewer Applications), ASTM F2881 (Standard Specification for 12 to 60 in. [300 to 1500 mm] Polypropylene [PP] Dual Wall Pipe and Fittings for Non-Pressure Storm Sewer Applications), and AASHTO M 330 (Standard Specification for Polypropylene Pipe, 300- to 1500-mm [12- to 60-in.] Diameter).
The growth of polypropylene pipes in the United States has prompted research into various mineral additives to enhance the performance and the sustainability of the products. There are several different types and grades of mineral additives that have been traditionally used in polypropylene, including calcium carbonate, talc, and glass fibers. The behavior of these additives in polypropylene can vary, depending on the size and grade of material, as well as the presence of interfacial modifiers and other treatments to the mineral additives and base resin.
In this research project, seven different pipes ranging in diameter from 300 mm to 1500 mm were manufactured with various blends of polypropylene (PP copolymer) and calcium carbonate (1.0 micron) masterbatches to see how their finished product properties were affected and to determine their compliance with the respective ASTM and AASHTO product standards. The calcium carbonate masterbatch loading rates ranged from 10% - 20%, and each masterbatch contained 80% calcium carbonate and 20% carrier resin, by mass. Both polyethylene and polypropylene carrier resins were evaluated. Material tests included melt index, density, Izod impact, tensile and flexural properties, and stress crack resistance testing via NCLS and UCLS. Finished product tests included impact testing and pipe stiffness. All tests were conducted in accordance with the AASHTO and ASTM standards. Long-term testing was conducted to evaluate compliance with the Florida DOT protocol for 100-year service life. Several different material formulations were also evaluated, and the life cycle impacts of the additives were assessed.
The results of the research project concluded that corrugated PP pipes can be manufactured with various types of mineral additives to meet or exceed the finished product requirements in the current ASTM and AASHTO standards for corrugated PP pipes. This significant finding will allow pipe manufacturers to incorporate more sustainable materials into their product formulations, improving performance, cost, and sustainability.
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