725SLIP LINING OF EXISTING PIPE

725.01Description

This work shall include installing a thermoplastic liner pipe into an existing pipe and filling the space between the liner pipe and the existing pipe with cellular concrete grout all in accordance with 105.03.

MATERIALS

725.02Materials 10

Materials shall be in acco rdance with the following:

Admixture .................................................................... * Cellular Concrete Grout .............................................. ASTM C869 Cement, Type I or Type III .......................................... 901.01(b) Foaming Agent ............................................................ 912.05 Profile Wall HDPE Liner Pipe .................................... 907.25(b) 20 Profile Wall PVC Liner Pipe ....................................... 907.25(c) Solid Wall HDPE Liner Pipe ....................................... 907.25(a) Water ........................................................................... 913.01 * An admixture may be used as recommended by and in accordance with the foaming agent manufacturer’s specifications. ** The supplier may elect to use gradations in accordance with

904.02(h) or may propose the use of alternate gradations

Where circular liner pipe is shown on the plans, the pipe structure shall be lined with solid wall HDPE liner pipe, profile wall HDPE liner pipe, or profile wall PVC 30 liner pipe. Where deformed liner pipe is shown on the plans, the pipe structure shall be lined with solid wall HDPE liner pipe or profile wall HDPE liner pipe.

The maximum number of joints and corresponding maximum length of each section of liner pipe used in each pipe structure to be lined shall be as shown on the plans. If the Contractor has obtained the necessary right-of-entry from all affected property owners and all necessary new permits or amendments to existing permits to enable work in areas accessible via Contractor-obtained right-of-entry, the Department will consider a written request by the Contractor to use liner pipe sections which exceed the maximum length shown on the pl ans. A corresponding reduction in the 40 maximum allowable number of joints shall be included with the written proposal. The Contractor shall not install longer sections of liner pipe until written approval has been received from the Engineer.

The liner pipe shall either be selected from those shown on the QPL of Thermoplastic Pipe and Liner Pipe Sources or shall be accompanied by a certification in accordance with 907.25 and 916. If the liner pipe is not on the QPL of Thermoplastic 725.02

Pipe and Liner Pipe Sources, then the certification shall be furnished. Liner pipe shall be submitted to the Engineer for review and approval prior to installation.

Proper care shall be taken to ensure that no damage is done to the liner pipe during the unloading process. All liner pipes sha ll be unloaded with straps and lifting equipment.

Liner pipe joints shall be bell and spigot , screw type, grooved press-on, butt fused, extrusion welded, or other joint as recommended by the liner pipe manufacturer and shall be installed according to the manufacturer’s recommended methods.

CONSTRUCTION REQUIREMENTS

Where a deformed HDPE liner pipe is specified, the liner pipe shall be made deformed by using equipment specifically designed to take a circular liner pipe and deform it without causing damage to the liner pipe. The equipment and method used to deform the liner pipe shall be described in the QCP. Once the liner pipe has been deformed, it shall be structurally reinforced in the horizontal and vertical planes. Structural reinforcement sha ll be spaced at a maximum di stance of 3 ft on centers. Structural reinforcement shall not be removed until the installation of the liner pipe and cellular concrete grout at that structure has been completed.

725.03Right-of-Entry Areas 70

If the Contractor desires more working room than the right-of-way provides, the Contractor may elect to purs ue rights-of-entry from all necessary adjacent property owners in accordance with 107.14. A temporary fence shall be installed as required to prevent encroachment of the public or livestock into the work area. Upon completion of the work, disturbed areas on private prop erty shall be restored in accordance with

107.14

725.04Quality Control

A QCP shall be submitted in accordance with ITM 803. No work on the pipe lining operation shall begin until written notice has been received that the QCP has 80 been accepted by the Engineer. Acceptanc e of the QCP in no way relieves the Contractor of the responsibility for installation procedures and testing requirements.

A QC representative shall be present at the jobsite for the initial testing of the first welding or fusing at each liner pipe installation location and for the joining, welding, or fusing of the liner pipe at each location.

725.05Filling of Cavities Outside of the Existing Pipe

All obvious cavities outside the existing pi pe shall be filled with non-removable flowable backfill in accordance with 213 prior to the liner pipe installation or with 90 cellular concrete grout placed in conjunction with the grouting operation after the liner pipe is installed.

725.03

725.06Joining Liner Pipe

Each liner pipe joint shall be welded, fused, or joined according to the manufacturer’s recommended methods. Welded liner pipe joints shall be welded with a continuous weld for the circumference of the liner pipe both inside and outside. Welded liner pipe joints shall have weld beads that are smooth and shall not project further than 3/8 in. into the inside of the liner pipe and shall not reduce the hydraulic capacity of the liner pipe. The ends of liner pipe that are to be welded or butt fused 100 shall be at the same temperature ±5º F.

A visual inspection will be conducted for acceptance of all liner pipe joined by methods other than by welding or fusing joints. All joints that do not pass visual inspection shall be removed, shall have a new joint fabricated, and will be re-inspected.

All liner pipe joints shall have sufficient mechanical strength to withstand the liner pipe installation and cellular concrete grouting operations.

Welding, butt fusing, or joining shall be performed by an operator trained and certified by either the manufacturer of the liner pipe or the manufacturer of the welding, butt fusing, or joining equipment. A copy of the operator’s certification shall be provided to the Engineer prior to the start of work. Prior to fabricating a production joint on a liner pipe, each operator who is performing welding, butt fusing, or joining, shall demonstrate that they can produce a joint that will withstand a destructive test prior to being allowed to join liner pipe. This test shall be repeated as many times as necessary to produce a joint that will pass the destructive test. One passing joint test is required per operator per contra ct. The method of joint testing shall be in accordance with section (b) or (c) below. 120

Solid Wall HDPE liner pipe joined using butt fusion shall be in accordance with ASTM F2620.

Solid wall HDPE liner pipe that is to have extrusion welded joints shall have destructive testing performed on a test section of liner pipe of the same material as the liner pipe being installed. The Contractor shall propose and describe in the QCP a destructive test, such as but not limited to a bend strap test, to demonstrate that an operator can produce an extrusion welded jo int that will not fail. Once an extrusion 130 welded joint is produced on a test section that passes the destructive test, each subsequent joint fabricated that same day by that operator will be visually inspected for acceptance. A destructive test in accordance with the QCP shall be conducted on the test section at the beginning of each day that solid wall HDPE liner pipe joining is being done.

Profile Wall HDPE liner pipe joined using extrusion welding shall be in accordance with ASTM F894. The Contractor shall propose and describe in the QCP 725.06

a destructive test, such as but not limited to a bend strap test, to demonstrate that an 140 operator can produce an extrusion welded joint that will not fail. Destructive testing shall be performed on two flat pieces of HDP E sheet stock that has been butt welded together to verify the extrusion gun is working properly and that the operator can produce an extrusion welded joint that will not fail. Once an extrusion welded joint is produced on a test section that passes th e destructive test, each subsequent joint fabricated that same day by that operator will be visually inspected for acceptance. A destructive test in accordance with the QCP shall be conducted on the test section at the beginning of each day that profile wall HDPE liner pipe joining is being done.

725.07Cellular Concrete Grout 150

The cellular concrete grout shall be designed in accordance with ASTM C869 except as herein modified.

The admixtures, retarders, and plasticizers used in the grout shall be in accordance with the foam concentrate supplier’s specifications.

The grout shall be made using the preformed foam process using foam generating equipment calibrated daily by the foam manufacturer to produce a precise and predictable volume of foam. The foam concentrate shall be certified by the manufacturer to have specific liquid/foam expansion ratio at a constant dilution ratio 160 with water.

The specific job mix shall be submitted to the Engineer by either the foam concentrate supplier or the certified or licensed grouting contractor for approval prior to use on the contract. The mix shall have a minimum 28-day compressive strength of 150 psi. The mix shall be tested by a laboratory qualified by the Department or shall be approved based on prior acceptable performance on Department contracts.

The cellular concrete grout pump gauges shall be calibrated a minimum of once per month in the presence of the Engineer by the method described in the QCP. 170

Grout mixed off site shall be delivered to the job site in a truck mixer in accordance with 702.09 filled to half its capacity. The foaming agent shall then be added to the cement mix in the truck and mixed to a uniform consistency.

Grout mixed on site shall be batched in a deck mate or similar device. Small batches of approximately 1 cu yd shall be mixed and pumped in a continuous operation.

For each day worked or for each 100 cu yds placed, four test cylinders measuring 180 3 in. by 6 in. shall be cast at the point of placement of the grout. Sampling, molding, curing, and compressive strength testing of the cylinders shall be in accordance with ASTM C495, except as modified herein.

Initial curing period shall be at a temperature of 70°F r10°F and shall be from 725.07

two to five days. After the initial curing, the test specimens shall be placed in a moist closet or moist room or stored in an enclosed curing tank above the water level. All specimens shall be kept in their molds in the moist storage for the remainder of the curing period. The specimens shall be tested at 28 days. At that time, the specimens shall be prepared for testing in accordance with ASTM C495, except the bearing 190 surface may be ground or cut with a dry saw to meet surface tolerance. The specimens shall not be capped. Specimens shall be tested in compression as rapidly as possible

to minimize drying. If more than one specimen is removed from the moist storage at

the same time, these specimens shall be covered with a damp cloth until time of testing.

A Type A certification in accordance with 916 shall be provided for cellular concrete

grout. The result of the compressive strength test shall be shown on the certification

for cellular concrete grout.

725.08Liner Pipe Installation

Prior to commencing the liner pipe installation, all jagged existing pipe edges or200

other deformities shall be repaired. All debris and foreign material shall be removed

from the existing pipe and disposed of in accordance with 203.08. A visual walk-

through inspection shall be performed after all debris and foreign material has been

removed from the existing pipe to assess the current condition of the pipe. If visual

inspection is not possible, a video inspection of the existing pipe shall be performed.

A copy of the video inspection shall be provided to the Engineer. If, upon completion

of the inspection of the existing pipe, the Contractor believes that they cannot proceed

with the work as shown on the plans, the Engineer shall be notified.

The cross-sectional area of the liner pipe shall be as shown on the plans.210

Prior to commencing the liner pipe installation operation, steps shall be taken to

verify that a liner pipe meeting the required cross-sectional area can be successfully

placed inside the existing pipe. If it is discovered prior to installation that a liner pipe

with the required opening area cannot fit, the inside and outside diameters of a

substitute liner pipe shall be submitted to the Engineer for approval. If this discovery

is not made until after the liner pipe installation has begun, the partially installed liner

pipe shall be removed. Inside and outside diameters for a substitute liner pipe shall

then be submitted to the Engineer for approval.

220

After the liner pipe installation is complete and the liner pipe has cooled to the

temperature of the existing pipe, the liner pipe shall be cut so that each end is 8 in.

outside the end of the existing pipe.

The cellular concrete grout within the annular space between the existing pipe and

the liner pipe shall be contained by bulkheads. The bulkheads shall be constructed at

each end of the structure. Each bulkhead shall be constructed to withstand the pressure

of the grouting operation. The bulkhead shall be free from leaks and the exterior

surface shall be given a smooth trowel finish. The bulkhead shall extend from the end

of the existing pipe inward a minimum depth of 18 in.230

725.08

816

Cellular concrete grout shall be injected into the annular space between the

existing pipe and the liner pipe. The injection operation shall provide sufficient cellular

concrete grout to fill all voids between the existing pipe and the liner pipe over the

entire structure length, but shall also be performed in a manner that does not distort

the liner pipe. Injection of the cellular concrete grout in lifts, use of spacers, or other

safeguards shall be taken to keep the liner pipe in position and prevent the liner pipe

from floating. The pressure developed in the annular space between the liner pipe and

the existing pipe shall not exceed the liner pipe manufacturer’s recommended

maximum value.240

All existing culverts, storm drains, underdrain pipes, drain tile, or other pipes that

are directly connected to the lined structure shall be perpetuated. Cellular concrete

grout shall not leak through the liner pipe at these connections.

725.09Method of Measurement

All thermoplastic liner pipe will be measured by the linear foot, for the shape and

cross-sectional area of the liner pipe, complete in place. Perpetuation of existing pipes

through the liner pipe will be measured by the number of existing pipes perpetuated.

250

No measurement will be made of liner pipe joints or the length of joint welding

or fusing, or other incidentals necessary to join sections of liner pipe in accordance

with the manufacturer’s recommendations. The liner pipe or flat sheet stock used for

destructive testing will not be measured for payment. No measurement will be made

of a liner pipe meeting the required opening area that does not fit.

No measurement will be made for debris removal and disposal, filling existing

voids, or trimming, cutting, jacking, or other corrective measures performed on jagged

edges or other deformities of the existing pipe to facilitate installation of the liner pipe.

No measurement will be made for visual or video inspection of the existing pipe.260

No measurement will be made for the bulkhead.

725.10Basis of Payment

The accepted quantities of thermoplastic liner pipe will be paid for at the contract

unit price per linear foot for the shape and cross-sectional area of the liner pipe,

complete in place. Perpetuation of existing pipes through the liner pipe will be paid

for by the number of existing pipes perpetuated.

Payment will be made under:270

Pay Item Pay Unit Symbol

Liner Pipe, Thermoplastic, Circular, _______sq ft ................... LFT

cross-sectional area

Liner Pipe, Thermoplastic, Deformed, _______ sq ft ............... LFT

cross-sectional area

Perpetuation, Existing Pipe ....................................................... EACH

725.09

817

The cost of repairing, trimming, or cutting jagged edges or deformities to existing280

pipe, filling cavities around the existing pipe with cellular concrete grout, acquisition

and restoration of right-of-entry areas, acquiring all necessary new permits or

amendments to existing permits to work in areas accessible via Contractor-obtained

right-of-entry, erection, maintenance, and removal of temporary fence, removal and

disposal of debris and foreign material from the existing pipe, visual or video

inspection of the existing pipe, deforming a circular liner pipe, supplying and

constructing the bulkheads, grouting the annular space between the existing pipe and

the liner pipe, and other incidentals will not be paid separately, but shall be included

in the cost of the pay items in this section.

290

The cost of liner pipe joints other incidentals necessary to join sections of liner

pipe in accordance with the manufacturer’s recommendations, and all test sections of

liner pipe and test sections of HDPE sheet stock shall be included in the cost of the

pay items in this section.

All costs associated with having a QC representative on site shall be included in

the cost of the pay items in this section.

The cost of training and certifying an operator, destructive and non-destructive

testing, liner pipe, and incidentals used in destructive testing, and all costs associated300

with the development of an acceptable QCP shall be included in the cost of the pay

items in this section.

Any joint that does not pass the visual inspection and needs to be re-fused, re-

welded, or re-joined shall be done at no additional cost to the Department.

In situations where the condition of the existing pipe requires that a substitute liner

pipe be utilized, there will be no reduction in payment for the installation of the

substitute liner pipe. There will be no additional payment for the additional cellular

concrete grout required to fill the larger void between the existing pipe and the smaller310

liner pipe.

There will be no payment for the installation or removal of any liner pipe that

cannot be successfully installed due to the condition of the existing pipe. There will

be no payment for a liner pipe meeting the required cross-sectional area that does not

fit.

If the existing pipe or any other object not designated for removal is damaged

while performing this work, it shall be considered unauthorized work and repaired or

replaced in accordance with 105.11.320

725.10