561.1 General Description
This work includes furnishing and inserting helically corrugated metal pipe, smooth-lined corrugated polyethylene pipe, high density polyethylene profile wall pipe, and high-density polyethylene solid wall pipe or a polyvinyl chloride pipe inside an existing metal pipe and pressure grouting the space between the two pipes.
561.1.01 Definitions
General Provisions 101 through 150.
561.1.02 Related References
A. Standard Specifications Section 801—Fine Aggregate Section 830—Portland Cement Section 831—Admixtures Section 844—Steel Pipe Section 845—Smooth Lined Corrugated Polyethylene (PE) Culvert Pipe Section 880—Water Section 882—Lime Section 883—Mineral Filler B. Referenced Documents GDT 84
561.1.03 Submittals
General Provisions 101 through 150.
561.2 Materials
Ensure that materials meet the requirements of the following specifications: Material Section Corrugated Steel Pipe (Helically Corrugated) 844.2.01* Smooth-Lined Corrugated Polyethylene (PE) Culvert Pipe 845 Portland Cement, Types I or II 830 Mineral Filler (Limestone Dust) 883 Fly Ash, Type A 831 Water 880 Fine Aggregate, Size No. 20 801.2.02 Agricultural Lime 882.2.02** *Use Georgia Standard 1030D to determine the metal thickness of the insert pipe. **For this Work, use agricultural lime that has 90 percent minimum passing the No. 30 (600 µm) sieve and 30 percent minimum passing the No. 200 (75 µm) sieve. A. High Density Polyethylene (HDPE) Profile Wall Pipe Use pipe liner that consists of a HDPE profile wall pipe that conforms to the requirements of ASTM F 894. Polyethylene material shall have polyethylene pipe liners material designation of PE 3408 and shall have a material cell classification per ASTM D 3350 of 334433C or higher. Join HDPE profile wall pipe liner by thermal fusion (extrusion welding) per manufacturer specifications or provide a positive mechanical joint that meets the requirements of ASTM D 3212. The joint shall be able to be pulled or pushed into the host pipe without joint separation. B. High Density Polyethylene (HDPE) Solid Wall Pipe Pipe liner shall consist of a HDPE solid wall pipe that conforms to the requirements of ASTM F 714 with an SDR of 32.5. Polyethylene material shall have polyethylene pipe liners material designation of PE 3408 and shall have a material cell classification per ASTM D 3350 of 345464C. Join HDPE solid wall pipe liner by butt fusion per ASTM F 2620 and the manufacturer specifications or provide a positive mechanical joint that meets the requirements of ASTM D 3212. The joint shall be able to be pulled or pushed into the host pipe without joint separation. C. Polyvinyl Chloride (PVC) Pipe Pipe liner shall consist of PVC corrugated pipe with a smooth interior that conforms to the requirements of ASTM F 949. PVC pipe shall have a minimum pipe stiffness of 46 psi (317 kPa) when tested according to ASTM D 2412. Use pipe made of PVC compound with a cell classification per ASTM D 1784 of 1245B. Join the PVC pipe liner with a PVC coupling that uses elastomeric sealing gaskets. The assembled joint shall meet the performance requirements of ASTM D 3212. The joint shall be able to be pulled or pushed into the host pipe without joint separation. Ensure that elastomeric seals meet the requirements of ASTM F 477. D. Grout Mixtures Mix water with the dry ingredients to produce a grout with an efflux time from the flow cone of at least 16 seconds and no more than 22 seconds when tested according to GDT 84. Add cement, cement and limestone dust, or cement and fine aggregate to the batch proportions to produce the required consistency. Table of Grout Mixtures Mix Proportions, Percent by Weight of Dry Materials Dry Materials Grout Types 1 2 3 4 5 Cement 25 25 25 25 100 Limestone dust 25 75 50 Fly ash 25 25 Fine aggregate 50 50
561.2.01 Delivery, Storage, and Handling
General Provisions 101 through 150.
561.3 Construction Requirements
561.3.01 Personnel
General Provisions 101 through 150.
561.3.02 Equipment
A. Batching Use weight hoppers and scales for each dry material or calibrated volumetric batch hopper. Calibrate volumetric batch hoppers in increments equivalent to one 94 lb. (42.6 kg) bag of cement. B. Mixing Use a watertight batch-type mixer capable of blending the various materials into a homogenous mixture. C. Grout Pumping Use a positive-displacement, piston-type pump or a screw-type worm pump equipped with the following: • Discharge line with a positive cut-off valve at the nozzle end and a by-pass return line to recirculate the grout back into a holding tank or mixer • A nozzle or device at the end of the discharge line that will remain secure in the 1 in. (25 mm) grout pipe and free of leaks D. Pulling Provide equipment capable of pulling the new helically corrugated metal pipe.
561.3.03 Preparation
General Provisions 101 through 150.
561.3.04 Fabrication
General Provisions 101 through 150.
561.3.05 Construction
A. Grout Mixtures Use the Table of Grout Mixtures in Subsection 561.2.D, Grout Mixtures. B. Installation Install pipe liner according to the manufacturer’s guidelines and as specified in the plans, with the following requirements: 1. Clean and inspect the existing pipe before pulling or pushing the new pipe through. 2. Use a nose cone on all on all pipe liners. The nose cone shall have enough strength to withstand pulling or pushing of the new pipe liner. Weld or bolt the nose cone to the end of the liner. Use a nose cone that includes a ring for attaching the pulling cable. 3. After pulling or pushing the new pipe through the old one, plug the space between the pipes at both ends with concrete or mortar. Insert a 1 in. (25 mm) grout pipe with threaded ends on the outside into the tops of the plugs at both ends of the pipes, and screw on a threaded cap. 4. After the pipe plugs have been in place long enough to develop strength to withstand pressure grouting, remove the grout pipe caps. Connect the grout pump to the downstream grout pipe and pump grout into the void until it flows freely from the upstream grout pipe. 5. After pumping is complete, replace the grout pipe caps.
561.3.06 Quality Acceptance
General Provisions 101 through 150.
561.3.07 Contractor Warranty and Maintenance
General Provisions 101 through 150.
561.4 Measurement
Renovating existing pipe is measured by the linear foot (meter) of the specified diameter of new pipe installed.
561.4.01 Limits
General Provisions 101 through 150.
561.5 Payment
Renovating existing pipe will be paid for at the Contract Unit Price bid per each diameter and metal thickness of new pipe. This payment will be full compensation for completing all work described in this Section, including cleaning and restoring damaged areas. Payment will be made under: Item No. 561 Renovating existing pipe____ in. (mm) diameter Per linear foot (meter)
561.5.01 Adjustments
General Provisions 101 through 150.
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