Highly engineered polymer that can be cast inside of an existing large diameter storm/sanitary sewer. This is an innovative structural repair system from Milliken Infrastructure. For more info please email steve.neschleba@milliken.com

1. GeoPolymer Mortar System for Structural
Rehabilitation of Sewer and Storm
Infrastructure

2. ©2014 Milliken Infrastructure Solutions, LLC
• Founded in 1865, Milliken is one of the world’s largest
privately held chemical and textile companies.
• Today, Milliken’s products and people encompass the
globe with over 7,000 associates working in more than
45 facilities worldwide, creating more than 19,000
products for our customers.
• Headquartered in Spartanburg, SC, Milliken is
recognized for global leadership in quality, safety,
environmental excellence and innovation.
Milliken & Company
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3. ©2014 Milliken Infrastructure Solutions, LLC
45 Facilities Around the World
Manufacturing
Design Center
Other
Research
Milliken & Company
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4. ©2014 Milliken & Company
You come in contact with Milliken products close to 50 times a day
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Fifty Times a Day
In Your Home…
Making food storage containers clear
Making duct tape both strong and tearable.
Making bathroom sinks, countertops, tubs and appliances anti-microbial.
Making your mattresses fire-resistant.
Making strong plastic parts in your household appliances.
Adding color to detergents, sponges, bowling balls washable paints & markers.
In household plastics, from laundry baskets to lawn furniture to drink cups.
In Retail…
Making plastic packaging – from caps to
bottles to blister packaging - on store
shelves clear or more colorful.
As retail floor coverings.
As fabric in store front banners and
awnings.
At Work…
In the infrastructure that delivers fiber
optic cable.
In the military uniforms and industrial
workwear that protect personnel.
As floor coverings for commercial,
applications, schools, health centers,
government buildings.
When Traveling…
As the floor coverings and fabrics in
airports, hotels and restaurants.
In luggage.
In automotive airbags, tires, belts &
hoses, trunks, and plastic parts.
At Play…
Reducing odor and improving comfort in
school sports gear, shoes and uniforms
In hunting garments.
In helmets, playground equipment,
watercraft and race car air dams .
In restaurant table linens and food
preparation areas.
In boats and canoes.
In Public Spaces…
Making hospital uniforms that resist stains and viruses.
In hospital, education and senior living center floor coverings.
Making active wound dressings to facilitate the healing of hard-to-heal wounds.
Making theater curtains more fire-resistant.
Making golf courses greener.
In bridges, boat ramps, ditches, & other transportation & infrastructure
applications.

5. ©2014 Milliken & Company
Innovation that lets us do good
for the world, create excellent
experiences for our customers
and build a sustainable business
that allows us to innovate for
the future.
Our Legacy of Innovation
Innovation has been core to Milliken since 1865.
Innovation that brings
together deep science,
meaningful design and
unique insights to bring a
new approach to
customer challenges.
Innovation that reflects the creativity and passion
of Milliken at our best.

6. ©2014 Milliken & Company
Milliken has been recognized
as one of the World's Most
Ethical Companies by
Ethisphere™ Magazine every
year since the first list in
2007.
Ethics

7. Milliken GeoPolymers

8. ©2014 Milliken Infrastructure Solutions, LLC
What is a GeoPolymer?
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• Not a Plastic
• Not HDPE/PVC/Epoxy
• Looks and feels like cement
• Workability
• Material Properties
• Service Life
• Chemical structure like natural stone
• Monolithic
• Durable
• Corrosion Resistant

9. ©2014 Milliken Infrastructure Solutions, LLC 9
GeoPolymer Chemistry Primer
Typical GeoPolymer Chemistry
Geopolymers or alkali cements consist predominantly alumino-silicates or
polymer Si-O-Al bonds and are similar in chemical make-up to natural
Zeolites. Traditional starting materials for geopolymers cements are fumed
silica, fly ash & metal slag.
• Geopolymers can be produced from
commercially available industrial
waste streams, creating a highly
environmentally friendly product.
• The chemical reactions of
geopolymer create only a fraction of
the CO2 emissions of standard
cementitious materials.
• Geopolymers have excellent
chemical and thermal resistance and
can essentially be considered
engineered stone.
Typical Geopolymer Structure
Source – J. Davidovits - Geopolymer Chemistry and Applications, 3rd ed.

10. ©2014 Milliken Infrastructure Solutions, LLC 10
GeoPolymer Products
GeoSpray Overview
Engineered
• High flexural and bond strength.
• High early and ultimate strength.
• Adapts to any shape, including bends,
curves, and angles.
Lower Total Cost
• Generally lower installation and
operating costs compared with
alternative methods
(SPR/CIPP/Slipline).
• Less disruption to the community
• Faster installation.
Sustainable
• Lower greenhouse gas emissions.
• 50%+ of raw materials come from
recycled industrial by-products.
• Locally manufactured.
Safe
• Styrene FREE.
• Contains no leachable toxins.
• Passed – EPA TCLP Toxicity
Characteristic Leaching
Procedure.

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GeoPolymer Products
GeoSpray Physical Properties

12. ©2014 Milliken Infrastructure Solutions, LLC
GeoPolymer Advantages
Self Bonding
Experimental Parameters:
• On the first day a series of 2” by 4”
cylinders were cast half full and cured with
on an approximately 45 angle.
• On subsequent days (1, 7, 14 and 28) the
top half of the cylinders were cast and
filled creating a 45 angled joint in the
center of the cylinders
• Compressive strength tests were conducted
28 days after the top half of the cylinders
were cast.
Joint in Tested Sample
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GeoPolymer Advantages
Self Bonding
Day 0 Day 1 Day 7 Day 14 Day 28
GeoSpray™
Day 0 Day 1 Day 7 Day 14 Day 28
Leading Portland Based Competitor
Results:
• Samples cast of GeoSpray (both halves)
when tested under compression did not
break at the joint.
• The chemical nature of GeoSpray allows
for chemical bonding across the interface
even with pours 28 days apart resulting
in a monolithic structure.
• Samples cast of competitive cement
mortars always broke along the angled
joint essentially creating 2 separate
layers.
This unique property of geopolymers allows project flexibility in variable
weather conditions as the covalent bonds prevent cold joint shear failure

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GeoPolymer Products
3rd Party Certified Testing
C1138M Abrasion Resistance of Concrete (Underwater Method Additions)
C779 Abrasion Resistance of Horizontal Concrete Surfaces
C403 Time of Setting of Concrete Mixtures by Penetration Resistance
C1260 Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)
C227 Potential Alkali Reactivity of Cement-Aggregate Combinations (Mortar-Bar Method)
C114 Chemical Analysis of Hydraulic Cement
C1543 Determining the Penetration of Chloride Ion into Concrete by Ponding
C1585 Measurement of Rate of Absorption of Water by Hydraulic-Cement Concretes
C642 Density, Absorption, and Voids in Hardened Concrete
C188 Density of Hydraulic Cement
C786 Fineness of Raw Materials by the 300-µm (No. 50), 150-µm (No. 100), and 75-µm (No. 200) by Wet
Methods
C1702 Measurement of Heat of Hydration of Using Isothermal Conduction Calorimetry
C156 Water Loss [from a Mortar Specimen] Through Liquid Membrane- Forming Curing Compounds for
Concrete
C597 Pulse Velocity Through Concrete
C900 Pullout Strength of Hardened Concrete
C136 Sieve Analysis of Fine and Coarse Aggregates
C666 Resistance of Concrete to Rapid Freezing and Thawing
C109 Compressive Strength of Hydraulic Cement Mortars (Using 2-in. or [50-mm] Cube Specimens)
C1012 Method for Length Change of Hydraulic-Cement Mortars Exposed to a Sulfate Solution
C452 Potential Expansion of Portland-Cement Mortars Exposed to Sulfate
C39 Compressive Strength of Cylindrical Concrete Specimens
C469 Static Modulus of Elasticity and Poisson's Ratio of Concrete in Compression
C496 Splitting Tensile Strength of Cylindrical Concrete Specimens
C512 Creep of Concrete in Compression
C78 Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading)
C1064 Temperature of Freshly Mixed Hydraulic-Cement Concrete
C138 Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete
C143 Slump of Hydraulic-Cement Concrete
C231 Air Content of Freshly Mixed Concrete by the Pressure Method
C191 Time of Setting of Hydraulic Cement by Vicat Needle
C157 Length Change of Hardened Hydraulic-Cement Mortar and Concrete
C1506 Water Retention of Hydraulic Cement-Based Mortars and Plasters
C187 Amount of Water Required for Normal Consistency of Hydraulic Cement Paste
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15. Installation

16. ©2014 Milliken Infrastructure Solutions, LLC 16
Structural Rehabilitation
Centrifugal Casting
Centrifugal Casting of GeoSpray
• Rapidly distributes material within the
pipe’s internal circumference
• Forms a strong, low permeability,
cement mortar lining
• Depending upon design & thickness,
creates a “pipe within a pipe” and does
not rely on the integrity of the host
structure
• While not generally required it is
compatible with most common
reinforcement technologies

17. ©2014 Milliken Infrastructure Solutions, LLC 17
Structural Rehabilitation
Application Process
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18. ©2014 Milliken Infrastructure Solutions, LLC 18
Structural Rehabilitation
GeoPolymer Mortar Solutions
Wall thickness range
1.5”-4”
Based upon specific design
requirements
Centrifugally Cast Concrete Pipe (CCCP) employs a similar spin casting
process as a non-structural mortar lining, but cementitious materials
are applied to a thickness that creates structural integrity of a whole
new pipe within the host structure.

19. ©2014 Milliken Infrastructure Solutions, LLC
A family of cementitious geopolymer mortar products designed for use in
the rehabilitation of pipes and structures in Chemical, Civil Infrastructure,
Mining, and Oil & Gas industries.
• Pipe Rehabilitation
Storm Water - Culverts
Sewer Water
Potable Water
• Transportation
Tunnels and Bridges
Roads
• Buildings and Structures
Commercial
Industrial
Milliken Geopolymers
Applications
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20. ©2014 Milliken Infrastructure Solutions, LLC 20
GeoPolymer Advantages
Application Flexibility
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Angles
 Bends, curves, and change in
elevation
Laterals
 Monolithically tied to structure
Host pipe material
 Brick, Rock, Concrete
 Corrugated Metal or Cast Iron
Host pipe condition
 Slightly to fully deteriorated

21. ©2014 Milliken Infrastructure Solutions, LLC 21
GeoPolymer Advantages
Application Flexibility
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Shape
 Non-round, elliptical, egg
shaped
 Manholes, wet-wells, junction
boxes
Length
 Short lines, culverts, point repair
 Longer sewer and storm
segments
Diameter
 From 36 inches to 180 inch
 Varying diameter in a single run
Ovality
 Ovality greater than 10%
 Box culverts and structures

22. ©2014 Milliken Infrastructure Solutions, LLC 22
GeoPolymer Advantages
Effective and Efficient
• Lower total system cost than
alternative methods
Installation + ongoing operating
costs
• Point of failure repair
• Less risk exposure from weather
• Less disruptive to the community
Less cost associated with road
closures, non-productive labor,
traffic delays, impact to local
business, etc.
• More quickly implemented
Less cure/set-up time
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