SLIP LINING SUBMITTALS

a. In addition of the submittals described in (1) above, submit the following for Slip lining a minimum of five (5) calendar days prior to the start of the grouting operation:

The proposed grouting mix and all performance data relative to this section such as, but not limited to: flow characteristics, viscosity, set time, bleed segregation, shrinkage and manufacturer.

The proposed densities.

The proposed grouting method.

The maximum injection pressures.

Twenty-four (24) hour and twenty-eight (28) day projected compressive strengths.

Proposed grout stage volumes.

Proposed bulkhead designs.

Grout flow control.

Buoyancy force calculations for the liner pipe.

Provisions for service connections and laterals.

b. These shall be submitted as a complete package for the grouting requirements and the Contractor shall notify the Engineer of any changes to be made at any time after approval is granted.

504.01.F MANUFACTURER’S CERTIFICATION

1. Furnish a certificate of compliance for all pipe and fittings furnished confirming that the materials supplied conform to the specified requirements. Include certified laboratory testing data

confirming satisfactory results were obtained on a sample of the pipe to be provided under the Contract.

2. Certification submitted to the City Engineer shall be sufficient to show the materials meet the specified requirements. Information and cut sheets shall be originals, copies will not be accepted. A minimum of five (5) original certification documents shall be provided. Costs associated with providing certification, including materials and testing, shall be borne by the Contractor.

504.01.G CURED-IN PLACE PIPE DESIGN PARAMETERS

1. Follow the design considerations of ASTM F-1216 and meet the following conditions and parameters:

Condition Parameter

Service Life...Greater than 50 years Pipe Conditions ...Fully deteriorated Load Conditions

Soil ...*

Traffic ...*, AASHTO HS-20-44 minimum Groundwater Elevation...*

Design Thickness ...Calculate and express this thickness as the absolute minimum thickness that will be acceptable (Minimum thickness allowed is 1/4 inch)

Pipe Ovality ...*, 2% minimum Modulus of Soil Reaction ...*

Enhancement Factor ...*

Long-term Flexural

Strength...50% of initial (ASTM D 790) Modulus of Elasticity ...50% of initial (ASTM D 790) Maximum Deflection...5%

Minimum Factor of Safety ...2.0

Resin Migration Allowance...10% maximum Allowable Deformity ...*

Minimum Thickness (=<10” dia.)...6 mm Minimum Thickness (>10” dia.) ...7.5 mm 2. * These parameters will be listed in the Special Provisions.

3. Design the CIPP wall thickness to withstand all imposed loads, including live loads and, if applicable, hydrostatic pressure. Include considerations for ring bending, deflection, combined loading buckling and ovality in the design of the CIPP.

504.02 MATERIALS

504.02.A HDPE PIPE

1. Furnish HDPE pipe meeting the requirements of ASTM D-3035 and Section 501.02.E and having a minimum SDR of 17. At the date of installation, the HDPE materials shall not be more than 6 months old from the date of manufacture.

504.02.B CURED-IN PLACE PIPE TUBE

1. Furnish CIPP tube that consists of one or more layers of absorbent non woven felt fabric meeting the requirements of ASTM F-1216, Section 5.1, ASTM F-1743, Section 5.2.1 and the following minimum standards:

Characteristic Test Method Polyester

Resin

Vinylester and Epoxy Resins

Flexural Strength ASTM D 790 4,500 psi 5,000 psi

Flexural Modulus of Elasticity ASTM D 790

Short-term 250,000 psi 400,000 psi

Long-term 125,000 psi 200,000 psi

2. Fabricate the tube to a size that when installed, conforms to the internal circumference and length of the original pipe. Make allowance for circumferential or longitudinal stretching during inversion. Provide flexible tubing exhibiting the following characteristics:

Be homogeneous across the wall thickness containing no intermediate or encapsulated elastomeric layers.

No part of the tube shall be less than 100 percent saturated by resin.

Shall have a relatively uniform thickness that when compressed at the installation pressures will equal or exceed the calculated minimum design thickness.

Shall not contain material that may cause delamination in the cured CIPP.

Shall be coated with an impermeable, flexible material on the outside layer of the tube (before inversion).

Seams shall be stronger than the non-seamed felt material.

504.02.C CURED-IN PLACE PIPE RESIN

1. Furnish CIPP resins meeting the requirements of ASTM F 1216, Section 5.2 and ASTM F 1743, Section 5.2.3. The resin installed CIPP liner system shall produce a CIPP that will comply with the structural requirements specified and be inert with respect to the flow media in the gravity pipe.

2. Provide resin that is compatible with the rehabilitation process, is able to cure in the presence or absence of water, and has an initiation temperature for cure as recommended by the resin manufacturer. Provide a general purpose or enhanced strength unsaturated, thermosetting, polyester, vinylester, or epoxy resin and a catalyst system compatible with the installation process.

3. Use a sufficient quantity of resin for tube impregnation to fill the volume of air voids in the tube with additional allowances for polymerization shrinkage and the loss of resin through cracks and irregularities in the original pipe wall. Use a serial vacuum impregnation process. Use a roller system to uniformly distribute the resin throughout the tube.

4. Color the resin with a pigment compatible with the resin system, as specified by the resin manufacturer, and reviewed by the City Engineer. Submit documentation from the resin manufacturer specifically describing the chemical characteristics of the resin system, including allowable mixing, impregnation, and handling time, transportation and storage time, and recommended curing cycle including temperatures, pressures, and times.

5. The resin manufacturer's documentation shall also include maximum allowable time for

handling the impregnated tube prior to insertion and the maximum allowable elapsed time from insertion to exotherm. If remedial measures are available to extend either of the maximum allowable times indicated above, without affecting the physical properties of the resin, the resin manufacturer shall describe these measures and the time limits beyond which even these measures will not prevent alteration of the physical properties of the resin.

504.02.D CURED-IN PLACE PIPE PERSONNEL

1. Perform CIPP installations with installers who are qualified, fully licensed, and certified by the manufacturer of the CIPP product system to be used on the Project. In addition, the installer shall have installed at least 50,000 feet of the CIPP product system.

2. Provide a manufacturer's representative with a minimum of two years experience with continuous in line mixing, wet out, and curing of CIPP in gravity pipes.

3. The manufacturer's representative shall be on-site during the initial CIPP wet out and cure. At other times when the representative is not on-site, provide the telephone number of a

manufacturer's representative who is available on a twenty-four (24) hour basis throughout the Project duration.

504.02.E PIPE BURSTING, FUSION, AND PIPE ASSEMBLY EQUIPMENT

1. Use equipment, approved by the pipe manufacturer and the City Engineer, designed for pipe bursting, slip lining, and butt fusion welding. Do not use copper or copper-alloy heating faces.

2. HDPE pipe jointing shall conform to Section 501.03.D.

504.02.F PERSONNEL QUALIFICATIONS

1. Operate butt fusion equipment with technicians who have been certified by the pipe

manufacturer and who have a minimum of two (2) years experience of butt fusion welding eight inch or larger diameter pipe liners.

2. Operate pipe bursting and insertion equipment with technicians who have a minimum of three years experience in the installation of HDPE pipe using slip lining technology and pipe bursting technology as appropriate.

504.02.G CELLULAR FOAM GROUT

1. GENERAL – Cellular grout for the annular space shall contain the same materials as neat cement grouts, blended with pre-generated aqueous foam to form macroscopic

non-interconnected air cells uniformly distributed throughout the grout. The "air cells" may account for up to 90 percent of the grout mix. Foam shall be added to the grout on-site by a licensed foam Contractor.

2. COMPRESSIVE STRENGTH – The grout shall have a minimum compressive strength of 25 psi in twenty-four (24) hours when tested in accordance with ASTM C-403 and a minimum of 100 psi in twenty-eight (28) days when tested in accordance with ASTM C-495 or C-109.

3. DENSITY – The Contractor shall design a grout mix with a density that will not float the pipe while maintaining an apparent viscosity that does not to exceed 18 seconds as tested in accordance with ASTM C-939. Density shall be verified by ASTM C-138 or by other methods as approved by the City Engineer.

4. PERFORMANCE REQUIREMENTS – The Contractor shall establish proposed grout material and mixes, equipment, placement procedures, applicator, set-up, and criteria that the grouting operations shall meet. The grouting system shall have sufficient gauges, monitoring devices and tests to determine the effectiveness of the grouting operation. The Contractor must document compliance with the project and slip liner pipe specification design limits. The grouting operation shall be modified if the grouting does not perform as submitted and not approved by the City Engineer.

5. MIX DESIGNS – Mixes shall be developed to completely fill the annular space between the host pipe and the liner pipe and shall meet the following requirements:

Accommodate the size of the annular void.

Accommodate the void size of the surrounding soil.

Accommodate the absence or presence of groundwater.

Provide the acceptable strength and durability.

Set-up or harden to prevent movement of the liner pipe.

Shrinkage shall not exceed 1 percent by volume.

6. GROUTING EQUIPMENT – The materials shall be mixed in equipment of sufficient size and capacity to provide the desired amount of grout material for each stage in a single operation.

The equipment shall be capable of mixing the grout at densities required for the approved procedure and shall also be capable of changing densities as dictated by field conditions any time during the grouting operation. Gauges shall be attached immediately adjacent to an injection port at the bulkhead; the gauge shall conform to an accuracy of no more than 2 percent error over the full range of the gauge operation.

504.03 CONSTRUCTION

504.03.A GENERAL

1. Handle and store all HDPE pipe to ensure that the pipe is not cut, gouged, scored, or otherwise damaged. Store the pipe so that it is not deformed axially or circumferentially. Before installing the pipe, inspect all liner pipe to verify its condition with the City Engineer. Cut out and remove from the site liner pipe segments with cuts, gouges, or scoring in the pipe wall exceeding 10 percent of the wall thickness. File a pipe condition inspection report with and receive approval from the City Engineer prior to installation.

2. For CIPP rehabilitation, remove existing lateral taps that protrude into the existing pipeline prior to beginning cleaning.

504.03.B PIPE JOINING

1. For approval of butt fusion welds, submit three qualification samples for each size of pipe liner to be welded. Make samples using the same materials, equipment, and methods to be used on the Project. Construct the test welds in the presence of the City Engineer. Joint strength shall be equal to that of the adjacent pipe and the pipe bead (1/8-inch to 3/16-inch in height) and be uniform and continuous around the entire circumference of the pipe, both inside and outside.

2. Use only cotton or other non-synthetic cloths to clean the inside and outside of pipe liner ends before welding.

3. Join sections of HDPE pipe liner in continuous lengths on-site above ground. Use butt fusion methods according to ASTM D-2657, Section 8 and the recommendations of the pipe liner manufacturer. Follow the cold weather procedures at all times. Electrofusion may be used for field closures as necessary when appropriate fusion equipment can be utilized in a trench type environment. For end sections or tail pipe, utilize electrofusion couplings.

504.03.C PIPE CLEANING

1. Flush and clean all parts of the existing gravity pipe system to remove all debris and obstructions. In addition, for host pipes repaired by CIPP, remove all mineral deposits, encrustation and grease. Cleaning methods may include washing with high-pressure water, mechanical removal, sandblasting of the walls, entry with hand tools, or other methods as approved by the City Engineer. Do not use chemicals without written approval of the City Engineer.

2. Conduct work that prevents blockage and minimizes surcharging in the sewer manholes and connecting sewer pipelines. Promptly repair damage to existing facilities as a result of the Contractor's work at no additional cost to the City.

504.03.D PRE-INSTALLATION CCTV INSPECTION

1. After cleaning, inspect the existing gravity pipe by CCTV inspection according to Subsection 501.03.Q.9 using personnel trained in locating breaks, obstacles, and service connections by video inspection. Prepare printed inspection reports that show the location in relation to an adjacent manhole of each infiltration point observed during inspection. In addition, note other points of significance such as locations of gravity pipe service connections, unusual conditions, roots, storm gravity pipe connections, sags, collapsed pipe sections, and broken pipe.

2. Provide the video and inspection reports to the City Engineer for review at least seven (7) calendar days prior to beginning CIPP installation, pipe bursting, and slip lining operations.

Some conditions noted in the inspection report may need to be corrected before continuing with the gravity pipe rehabilitation.

504.03.E RECEIVING PITS AND INSERTION PITS

1. Locate all pits to suit the specified pipe lining operation.

2. Use existing manholes where practical. Remove manhole inverts, benches, and channels to permit access for installation equipment. Enlarge the input and output pipe openings if required to accommodate the maximum outside diameter size of the insertion equipment. Do not put undue stress on existing structures. Reinstall inverts and reconstruct benches and channels after pipe liners have been installed.

3. In areas where new manholes are not being installed or existing manholes are not available, excavate and restore pits at no additional cost to the City. This may include providing a new manhole if an existing manhole is removed or damaged.

504.03.F PROPERTY OWNER NOTIFICATION

1. Notify all affected parties in writing forty-eight (48) hours prior to beginning pipe liner installation.

When work has been stopped for at least seven (7) calendar days, notify all affected parties again twenty-four (24) hours prior to resuming work. Make personal contact with any party that cannot be reconnected within the time stated in the written notice. Before entering private property, obtain permission from the property owner.

2. When it is necessary to shut down a private service lateral to perform the rehabilitation work, notify all the affected parties one week prior to and again forty-eight (48) hours prior to the shutdown. Gravity pipe service shall not be out of service for more than eight (8) hours and not between 6:00 p.m. and 8:00 a.m.

504.03.G BYPASS PUMPING

1. Provide bypass pumping consisting of furnishing, installing, and maintaining all power, primary and standby pumps, appurtenances, and bypass piping required to maintain existing flows and services in accordance with Section 204.

504.03.H SAGS IN LINE REPAIR

1. If the pre-installation CCTV inspection reveals a sag in the existing gravity pipe greater than one-half the diameter of the existing pipe, install replacement pipe such that it has an

acceptable grade without sags. Take necessary measures to eliminate these sags by replacing the pipe, or digging a sag elimination pit and bringing the bottom of the pipe to a uniform grade in line with the existing pipe invert, or by other measures that are acceptable to the City Engineer.

504.03.I POINT REPAIRS

1. Repair the pipe where point repairs are shown. If the pre-installation video inspection reveals an obstruction that cannot be removed by conventional gravity pipe cleaning, upon approval from the City Engineer, make a point repair to uncover and remove or repair the obstruction prior to lining. Point repairs not shown will be paid for as Extra Work when approved by the City Engineer.

504.03.J INSTALLATION 1. PIPE BURSTING

a. Break existing pipe by utilizing a constant tension system with a hydraulic or pneumatic bursting device that breaks away the pipe. A static "cone cracking" method may be used, but only by advancing the mole bursting head with a "solid steel tow rod" pulled by a constant tension hydraulic pulling wrenching system. The advancement of the bursting mole head with a chain is not allowed.

b. The void created by the bursting device shall be of sufficient size to accommodate the HDPE pipe. Install the HDPE pipe immediately after the void has been formed by bursting.

Continue pipe bursting without interruption from one manhole to another manhole unless the City Engineer allows otherwise. Extend the HDPE pipe 12-inches into the manhole or concrete structure past the inside wall and allow a minimum of 4 hours or longer as recommended by manufacturer, for the pipe initial contraction/relaxation after installation.