SBIR-STTR Award

This Phase I research is intended to evaluate the feasibility of manufacturing low-cost, acid-resistant sanitary sewer pipe from sulfur concrete. Sulfur is an abundant mineral recovered from coking, natural gas processing, and petroleum refining. Secondary recovery of sulfur, resulting from environmental regulation, produces more material than is needed by U.S. industry.The U.S. Bureau of Mines developed a process by which elemental sulfur can be used as a thermal cement with aggregate fillers to make concrete. Sulfur concrete appears to be a good solution to solve the problem of deteriorating sewerage structures made from Portland cement. Portland cement is alkaline and has been found to perform poorly in the acid environment in most sanitary sewer systems. Alternative materials that can solve the problem of premature failure of concrete pipe are expensive. The purpose of this Phase I project is to develop a low-cost alternative to traditional concrete pipe.

This Phase II, research project is intended to make the process of manufacturing sulfur lined Portland cement concrete pipe and manhole components a reality. Concrete pipe has many positive attributes such as strength and low cost. However, it is not an effective material in an acid environment. Feasibility studies performed in Phase I demonstrated the viability of the lining process. Phase II concentrates on quality control during manufacturing and a demonstration project where the product will be put into use.During the first year, full-scale equipment will be designed and built and the manufacturing process will be refined in a laboratory. The second year involves using the equipment on concrete precast sites to provide product for demonstration projects. Measurements of life span, joint capacity, and strength of the pipe will be made to evaluate product performance.