602Rehabilitation of Culvert and Storm Drain Pipe

(Last Revised May 2024)

602-1DESCRIPTION. Rehabilitate culvert and storm drain pipe in accordance with these

specifications, the contract documents, and as directed by the Engineer.

602-2MATERIAL REQUIREMENTS

602-2.01General. Materials requirements are specified in the following subsections:

Portland Cement Concrete 501 Shotcrete 583 Concrete Repair Material 701-04 Vertical and Overhead Patching Material 701-08 Concrete Repair Material - High Early Strength 701-12 Grout Sand 703-04 Cured in Place Pipe (CIPP) Liner 706-09 Polyvinyl Chloride Pipe (relining) 706-10 (Profile Wall) (Corrugated) High Density Polyethylene Pipe (HDPE) (relining) 706-11 (Profile Wall) (Smooth Wall) Corrugated Steel Pipe 707-02 (Polymer Coated) Tunnel Liner Plate (relining) 707-05 Structural Steel Plate for Pipe, Pipe Arches and Underpasses 707-08 Corrugated Structural Steel Plate for Pipe and Pipe Arches and Underpasses 707-09 Anchor Bolts for Corrugated Culverts 707-20 Zinc Chromate Primer 708-04 602-2.02 Section 600 STANDARD SPECIFICATIONS (USC) January 1, 2026 VOLUME 3 Bar Reinforcement, Grade 60 709-01 Wire Fabric for Concrete Reinforcement 709-02 Stud Shear Connectors 709-05 Membrane Curing Compound 711-05 Admixtures 711-08 Flowable Fill 733-01

602-2.02Grout for Annular Space. Design the grout for the annular space between the existing pipe

and new liner pipe in accordance with the pipe Manufacturer’s recommendations. Grout for the annular space shall be in accordance withthe requirements of Controlled Low Strength Material (CLSM) (No Fly Ash) of 733-01 Flowable fill. Calculate the required volume of grout based on the existing culvert/storm drain internal diameter (minus deformations) and the external diameter of liner pipe. All grout components must appear on the Approved List unless approved by the Director, Materials Bureau.

602-3CONSTRUCTION DETAILS. Provide the Engineer, a minimum of 10 days prior to starting of

the work, a written proposal of how the work will be progressed. The proposal shall include dewatering of the pipe; procedures for maintaining line and grade of the lining pipe, pipe manufacturer’s recommendations for the assembly of preapproved joints, or joint fusion methods; bracing methods; grout mix design; and void filing techniques. Such proposals are also required, regardless of the rehabilitation method, for shotcreting, concrete, and void filling methods.

602-3.01Existing Pipe Preparation. Dewater, clean and inspect the existing pipe. Determine the

location of and remove obstructions that may prevent proper installation of the paving or lining material. Inspect small inaccessible pipes, generally less than 48 inches in diameter, using a closed circuit television and camera to provide a visual inspection. Provide strutting and bracing as required to ensure stability of the pipe.

602-3.02Handling & Installing Lining Materials

identified in the contract documents or approved by the Engineer. Do not allow water to flow along the invert during concrete or fill material placement.

Structural Plate Pipe with the exception of the following:

the corrugations and concrete reinforcement details as indicated on the plans. If welding has been used to anchor the reinforcement or studs on a galvanized section of the pipe then upon completion of the anchoring, restore the coating in accordance with §702-02 Corrugated Steel Pipe, E. Coating Repair. Coating restoration is not required where mechanical anchoring of the reinforcement has been utilized.

the appropriate mix design requirements specified in Table 2 of Materials Procedure (MP) 501-2 Mix Design and Approval Procedure for Performance Engineered Mixtures – Structural Concrete for paving of the invert.

the following: 602-3.02 Section 600 STANDARD SPECIFICATIONS (USC) January 1, 2026 VOLUME 3

plans. If welding has been used to anchor the reinforcement or studs on a galvanized section of the pipe then upon completion of the anchoring, restore the coating in accordance with §702-02 Corrugated Steel Pipe, E. Coating restoration is not required where mechanical anchoring of the reinforcement has been utilized.

shotcrete layer limits along the periphery will be indicated on the plans.

shall appear on the Department’s Approved List of Materials and Equipment, Rehabilitation of Culverts and Storm Drains section. The CIPP contractor shall provide the Engineer a report with design details and calculations for determining the minimum required thickness of the cured-in-place-pipe (CIPP) liner, the minimum internal pressure required to hold the wetted liner tight against the host pipe, and the maximum allowable internal pressure so as not to damage the wetted liner. All design calculations shall assume a fully deteriorated host pipe, unless Item 602.37xx, Lining Concrete pipe with Cured in Place Pipe (CIPP), is specified. All liner installations require the excavation of a resin containment pit to facilitate the installer’s collection and subsequent disposal of any waste (styrene or non-styrene) and / or curing water from the jobsite. When the liner curing is completed, the installer will remove all waste prior to the lined pipe being put back in service. The plans will indicate the size of the excavation for the resin containment pit. The excavation, temporary storage of the fill and restoration of the downstream channel will be performed under Section 206-1.02, measured under 206-4.04 and paid under 206.0201 Trench, Culvert and Structure Excavation – O.G. Use a resin / liner system meeting the following criteria: -System consists of one or more layers of flexible needled felt or an equivalent material as approved by the Materials Bureau. -Liner is flexible enough to fit irregular pipe sections and able to negotiate pipe bends. Liner’s surface must be coated with a plastic material compatible with the proposed resin. All liners containing styrene based resins require the use of a pre liner, to be inserted into the existing pipe before insertion of the CIPP liner. In addition to the pre liner, single or double sided liners may be specified in the contract plans, depending on the environmental setting of a particular application. A thermoset resin and catalyst or an epoxy resin and hardener system, compatible with the proposed inversion system shall be used. If indicated in the contract documents, a resin containing less than five percent volatile organic compounds (VOCs) with less than 0.1 percent hazardous air pollutants (HAPs) and less than 0.1 percent of water quality pollutants as listed in 6 NYCRR Parts 700-705 shall be supplied. If the resin type (styrene or non-styrene) is not specified on the plans, the installer has the option to select the resin type. Proposed resin shall be compatible with the proposed inversion process. Vacuum impregnate the liner with resin. Use a volume of resin capable of filling all voids in the liner material at nominal thickness and diameter. Adjust this resin volume by adding a minimum of 5% excess resin to allow for changes in resin volume due to polymerization and for any resin migration into the cracks and joints of the original pipe.

hydrostatic head, air pressure inversion, or a combination of the two. Do not exceed the manufacturer recommended maximum pressure to the liner felt fiber during the inversion process. 602-3.02 Section 600 STANDARD SPECIFICATIONS (USC) January 1, 2026 VOLUME 3 Pulled in place installations may be allowed if it is indicated on the contract documents or if the installer is given prior approval by the Director, Materials Bureau.

minimum required pressure between the CIPP liner and the existing (host) pipe. The lower end of the liner must extend beyond the outlet end whenever possible. Where changes in elevation may create excessive stresses on the liner felt, the use of bulkheads may be necessary. Alternative installation methods using a hydrostatic head will be subject to approval by the Director, Materials Bureau.

point. The air pressure needs to be adjusted and sustained to a level capable of holding the liner against the host pipe regardless of the curing method proposed to be used.

the temperature of the water above the level required to cure the resin. Monitor and record both the temperature of the curing water exiting the heating source and the temperature of the curing water returning to the heating source. Monitor and record the observed temperatures by the remote sensors on the liner-host pipe interfaces, located in the upstream and downstream area of the pipe. The remote temperature sensors readings will be used for monitoring the progress of curing and its duration. The minimum curing time is the sum of the minimum recommended initial and post-curing times as per the liner resin supplier’s recommendations. The onset of the initial curing approximately occurs when all remote temperature sensors register a temperature consistent with the “exotherm”, which shall be included in the Manufacturer’s recommendations. Post-cure the liner at least for the minimum post-curing time and at the minimum post-curing temperature level, as per the liner Manufacturer’s recommendations. Add post-curing time for any deviations from the recommended post-curing temperature levels. All resin Manufacturers’ curing proposals require approval by the Director of Materials Bureau prior to its initial use by the Department. Also, a new curing proposal submission for approval is required if an already approved liner Manufacturer introduces a new resin formulation and/or a new liner curing method to a Department contract. .

so that it does not cause or contribute to a violation of water quality standards to receiving waters or groundwater 6 NYCRR Part 700-704. In particular, the CIPP Contractor shall note the surface water quality and groundwater standards at 6 NYCRR Part 703 for pollutants such as styrene and thermal discharges. The CIPP Contractor shall enquire as to the classification of potential receiving surface waters in the project location if this information is not provided in the contract documents.

location; and/or

within vehicles that have a waste transporter permit 6NYCRR 364. Off-site disposal shall be at a publicly owned treatment works or at a disposal facility permitted to accept the wastewater. The Contractor shall conduct off site treatment to reduce styrene concentrations to acceptable levels to meet water quality standards prior to discharge to the receiving waters; and/or 602-3.02 Section 600 STANDARD SPECIFICATIONS (USC) January 1, 2026 VOLUME 3

receiving waters in accordance with agreements received from the Regional NYSDEC Office.

described in A1 and A2 above or discharge on site if it does not contain pollutants that could cause or contribute to a violation of water quality standards. Reduce temperature to prevent a violation of the thermal standards to the receiving waters.

the installation for disposal.

record/documentation of the reuse and/or disposal facility and quantity disposed of curing water leaving the site. After post-curing is completed, cool the liner to a temperature of 100o F prior to relieving the static head in the inversion standpipe. Cool-down may be accomplished by adding cool water into the inversion standpipe to replace warm curing water being removed from the liner. Contract documents may contain restrictions on the temperature of the released curing water or whether the curing water needs to be removed and treated. Any other proposed liner curing methods will be subject to the approval of the Director, Materials Bureau.

length of an inversion run and be free of dry spots, lifts and delaminations. If any dry spots, lifts and delaminations exist, remove the liner in those areas. Mark a line 3 feet from both ends of the distressed area, cut the distressed area out, and replace it at no cost to the Department. If the Cured-In Place-Pipe (CIPP) liner does not fit against its termination point, seal the space between the pipe and liner with a resin mixture compatible with the CIPP. The liner may be sampled and tested for tensile and flexural properties in accordance with ASTM F 1216 at the discretion of the Department. Failure to meet the designed properties will be a cause for liner rejection.

after the liner has been cured in place. Use robotic cutting devices to reestablish tie-ins in non- man accessible pipes.

through the existing pipe to verify liner clearance. The liner must be positioned and secured to facilitate its complete encapsulation by grout. Follow the Manufacturer's recommendations for handling and assembling the pipe and all provisions included in the approved written proposal. When required, reconnect existing storm drain lateral connections by utilizing an open cut excavation, internal connection or remote installation using robotics. Prior to filling the annular space, connect and seal all laterals between the new liner pipe and the existing lateral. Grout the entire annular space. Provide a minimum annular space of 1 inch for grouting between the new and existing pipes. Provide details on how to hold the liner pipe to line and grade until the grout has set. If the volume of the grout used is less than the anticipated (calculated) volume, or an inspection of the relined culvert indicates that there are voids in the annular space, the Contractor must provide the EIC with a plan to rehabilitate all identified voids. Depending on the location and size of the voids, 602-3.02 Section 600 STANDARD SPECIFICATIONS (USC) January 1, 2026 VOLUME 3 additional grouting may be required in these areas. This may be accomplished by re-grouting in those areas from within the culvert. The voids must be filled to the satisfaction of the Engineer at no additional cost to the state. Grout that fills invert and connected voids is covered in the cost for these items.

provisions of §602-3.02 E. Lining with a new Liner Pipe – General. Reline with Smooth Wall Polyethylene Pipe or Profile Wall Polyethylene Pipe, as indicated in the contract documents. Install all pipe, fittings, adapters and appurtenances according to the Manufacturer’s recommendations. Limit joint separations to less than ½ inch between adjoining sections. Field cuts will be permitted only at the terminal ends. No HDPE pipe sections less than 3 feet long will be allowed in any lining projects. Perform all butt fusion, welding and extrusion welding of HDPE pipe in accordance with the Manufacturer’s recommendation. A Manufacturer’s representative – or an individual trained by the manufacturer – must be present at all times during any fusion or welding operations. Alternate joining methods will be subject to approval by the Director, Materials Bureau.

§602-3.02 E. Lining with a new Liner Pipe – General. Reline with a Profile Wall PVC Pipe or Corrugated Wall PVC Pipe with integral bell and spigot joints. The installation proposal for this item to be submitted by the contractor for Departmental approval should in addition address the following PVC specific issues prior to any work approval is granted; Whether the PVC liner will be pulled or pushed through the culvert and the type of pushing or pulling ring/plate to be used; Whether a nose cone or a different device will be used in this process and how the jacking, pulling or pushing loads on the liner will be monitored in order to conform to the PVC liner’s Manufacturer’s specifications and guidelines. Include PVC liner’s Manufacturer’s specifications and guidelines in the submitted for approval proposal. Follow all Manufacturer’s recommendations during joint assembly operations.

Pipe Arch. Prior to lining, follow in its entirety all provisions of §602-3.02 E. Lining with a new Liner Pipe – General. Insert and brace the liner pipe to the specified line and grade, and align adjacent pipe sections such that port holes, if used, are placed as detailed in the contract plans (Alignment bolts are not adequate bracing by themselves). Sever all alignment bolts not fully turned out and grind them flush to the new pipe interior. If port holes are used, provide fittings and plugs compatible with the delivery equipment. Insert the plugs into the fittings as the operation is completed. Limit joint separations to ½ inch between adjoining sections. To ensure that grout remains in the annular space, place internal expanding joint bands with annular corrugations and foam gaskets at each joint. Before grouting the annular space, brace and strut the bands. Do not obstruct with any bracing material the flow of grout into the annular space. Remove the bracing, struts and bands upon completion of this work.

Prior to lining, follow in its entirety all provisions of §602-3.02 E. Lining with a new Liner Pipe – General. Align adjacent pipe sections such that port holes, if used, are placed as detailed in the contract plans. If port holes are used, provide port hole fittings and plugs compatible with the delivery 602-3.03 Section 600 STANDARD SPECIFICATIONS (USC) January 1, 2026 VOLUME 3 equipment. Insert the plugs into the fittings as the grouting operation is completed. Alignment bolts are not adequate bracing by themselves. Sever all alignment bolts not fully turned out and grind them flush to the new pipe interior. Do not obstruct with any bracing material the flow of grout into the annular space. Once lining with this item has been completed, apply §603-3.07 Concrete Paving for Corrugated Structural Plate Pipe and as indicated in the contract documents.

§602-3.02 E. Lining with a new Liner Pipe - General. Line with tunnel liner plates (double flange). Use a lap type longitudinal seam. Fabricate the lap to allow a continuous cross section of the plates through the seam. Use an offset depth equal to the metal thickness for the full width of plate, including flanges. Drilling, punching or drifting to correct defects in manufacturing will not be permitted. Plates with improperly punched holes will be rejected. Use 5 bolts per 18 inch width of plate in each lapped longitudinal joint and stagger the bolts in the ridges and valleys. Follow the Manufacturer’s recommendation for circumferential and longitudinal bolt spacing.

with a new Liner Pipe – General. All welders are to be NYS certified. Reline with a structural steel plate that has welded, flush joints in the shape, thickness and dimensions shown in the contract plans. Align adjacent pipe sections such that port holes, if used, are placed as detailed in the contract plans. If port holes are used, provide port hole fittings and plugs compatible with the delivery equipment. Insert the plugs into the fittings as the grouting operation is progressed. All sections shall be properly braced such that there is no deformation of the liner during installation. All sections will be completely welded and in place prior to grouting. Drilling, punching, or drifting to correct defects in manufacturing will not be permitted. Ensure Bracing material and the methods do not obstruct the flow of grout into the annular space

602-3.03Damaged Pipe and Repair. Repair all damage to the existing host pipe caused that is strictly

obstructing the progress of the relining operation. Repair any damage to the newly installed liner caused during construction, consistent with recommendations of Section 603- 3.04 Damaged Pipe and Repair.

602-4METHOD OF MEASUREMENT

602-4.01Lining with new pipe. This work will be measured as the number of feet along the bottom

centerline, measured to the nearest foot.

602-4.02Paving inverts. This work shall be measured as the number of square feet determined by the

paved width measured along the pipes interior circumference at the top of the corrugations and the length along the centerline of the pipe measured to the nearest square foot.

602-4.03Shotcreting. This work shall be measured as the number of square feet determined by the

shotcreted width measured along the pipes interior circumference at the top of the corrugations and the length along the centerline of the pipe measured to the nearest square foot.

602-5BASIS OF PAYMENT. Include the cost of furnishing all labor, materials, and equipment

necessary to complete the work in the unit price bid. Include the cost of all fill material needed to fill the annular space between the existing pipe and the liner pipe, dewatering and cleaning of existing pipe, and the removal of any obstructions, intrusions or damaged pipe prior to lining. Section 600 STANDARD SPECIFICATIONS (USC) January 1, 2026 VOLUME 3 For Paving Inverts and Shotcreting, include the cost of furnishing all labor, materials and equipment necessary to complete the work for the unit price bid and include all necessary preparations such as dewatering and cleaning to the existing pipe. For Cured in Place Pipe, include the cost of furnishing all labor, materials and equipment necessary to complete the work for the price unit bid and include all necessary preparations such as dewatering and cleaning to the existing pipe, all activities involving water treatment as well as water and waste transportation and disposal. The excavation for the resin containment pit, temporary storage of the fill and restoration of the downstream channel will be paid for under 206.04 Trench and Culvert Excavation – O.G. Payment will be made under: Item No. Item Pay Unit

602.2002 Structural Paving of Inverts with Portland Cement Concrete Square Feet

602.2101 Lining Culvert with Shotcrete Square Feet

602.25xx Lining with High Density Polyethylene Pipe Feet

602.26xx Lining with Smooth Wall High Density Polyethylene Pipe Feet

602.27xx Lining with Profile Wall High Density Polyethylene Pipe Feet

602.30xx Lining with Polyvinyl Chloride Pipe Feet

602.36xx Lining with Cured in Place Pipe (CIPP) Feet

602.37xx Lining Concrete pipe with Cured in Place Pipe (CIPP) Feet

602.4xynnn Lining with Structural Steel Plate for Pipe, Pipe Arches and Underpasses Square Feet x – Thickness (2= ½ inch, 3= ¾ inch, 4=1 inch, 5=1⅛ inch, 6=1¼ inch, 7= 1⅜ inch) y- Shape (1= Arch, 2=Box, 3=Horizontal Ellipse, 4=Vertical Ellipse, 5=Round) nnn=serialized pay item

602.51xxxx Lining with Corrugated Steel Structural Plate Pipe

with PCC Paved invert Feet

602.53xxxx Lining with Corrugated Steel Structural Plate Pipe Arch

with PCC Paved invert Feet

602.550101 Lining with Steel Tunnel Liner Plate 10ga Square Feet

0102 Lining with Steel Tunnel Liner Plate 8ga Square Feet

0103 Lining with Steel Tunnel Liner Plate 7ga Square Feet

0104 Lining with Steel Tunnel Liner Plate 5ga Square Feet

0105 Lining with Steel Tunnel Liner Plate 3ga Square Feet

602.75xx Lining with Polymer Coated CSP 12ga, (2- 2/3”x1/2”) Feet

602.76xx Lining with Polymer Coated CSP-Arch 12ga, (2- 2/3”x1/2”) Feet602.80xx Lining

with Polymer Coated CSP 12ga, (3”x1”) or (5”x1”) Feet

602.81xx Lining with Polymer Coated CSP-Arch 12ga, (3”x1”) or (5”x1”) Feet

Refer to Contract Proposal for full Item Number and full description.