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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Section 600 STANDARD SPECIFICATIONS (USC) January 1, 202 4 VOLUME 3 The Contractor shall fill gaps at the edges of the paved area with cut pavers or edge units. The Contractor shall adjust pattern at pavement edges such that cutting of edge pavers is minimized. All cut pavers subject to tire traffic shall be no less than o ne-third (1/3) of a whole unit. After pavers are placed on the adhesive, set them in it with at least one pass of a minimum 300 pound hand roller. Replace any cracked units with whole units and set them with the hand roller. Polymeric sand shall be swept over the precast concrete street pavers until the joints are completely filled. The paver surface shall be swept clean and the joints lightly wetted with water. This joint filling operation shall not be performed if the air te mperature is expected to fall below 40ºF, or there is an expectation of rain within 4 hours of the completion.
601-4 METHOD OF MEASUREMENT. Architectural pavements and treatments will be measured by
the number of square yards placed.
601-5 BASIS OF PAYMENT. The unit price bid per square yard shall include the cost of all labor,
materials and equipment necessary to satisfactorily complete the work, including setting bed material, except that any sawcutting of existing pavement, excavation, concrete base, curb, curb and gutter, and subbase course will be paid for separately. Payment will be made under: Item No. Item Pay Unit 601.01 Precast Concrete Street Paving (Bituminous Setting Bed) Square Yard SECTION 602 - REHABILITATION OF CULVERT AND STORM DRAIN PIPE (Last Revised January 2019)
602-1 DESCRIPTION. Rehabilitate culvert and storm drain pipe in accordance with these
specifications, the contract documents, and as directed by the Engineer.
602-2 Material Requirements.
602-2.01 General. 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
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Section 600 STANDARD SPECIFICATIONS (USC) January 1, 202 4 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 Lightweight Concrete Fill (Type A or B) 733-01
602-2.02 Grout 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 with 733 -01 Lightweight Concrete Fill (Type B). 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.
602-3 CONSTRUCTION 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 manufa cturer’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.
602-3.01 Existing 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.
602-3.02 Handling & Installing Lining Materials
A.General. Install each run of lining pipe with the same material for the entire run unless otherwise 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.
B.Structural Paving of Inverts with Concrete . Apply §603 -3.07 Concrete Paving for Corrugated Structural Plate Pipe with the exception of the following:
1.Pave the area along the invert’s periphery, providing concrete cover thickness over the crests of 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 req uired where mechanical anchoring of the reinforcement has been utilized.
2.Use Class D, Class H or Class J concrete for paving of the invert.
C.Lining with Shotcrete. Apply all requirements of Section 583, Shotcrete with the exception of the following:
1.Shotcrete may be used to line concrete pipe, stone arches, and corrugated metal pipes.
2.All reinforcement design and details (e.g. spacing, anchoring, etc.) must be indicated on the plans. If welding has been used to anchor the reinforcement or studs on a galvanized section of
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Section 600 STANDARD SPECIFICATIONS (USC) January 1, 202 4 VOLUME 3 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.
3.Apply a minimum 2 inch thick shotcrete layer over the crests of the corrugations. The shotcrete layer limits along the periphery will be indicated on the plans.
D.Lining with Cured in Place Pipe (CIPP) Liner. The CIPP manufacturer’s / installer’s name 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 agai nst 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 specif ied. 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, th e 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 c hannel 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. I f the resin type (styrene or non -styrene) is not specified on the plans, the installer has th e 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.
1.Installation. A cured -in-place -pipe (CIPP) liner may be installed into the host pipe by 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. 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.
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Section 600 STANDARD SPECIFICATIONS (USC) January 1, 202 4 VOLUME 3 a. Hydrostatic Head. The standpipe height must be sufficient to maintain at least the 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.
b.Air Pressure. The liner may be inverted using air pressure to extend it to the termination 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.
2.Curing. Cure the liner by circulating heated water throughout the section. Uniformly raise 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 inter faces, located in the upstream and downstream area of the pipe. The remote temperatu re 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 t he 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 Burea u 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 Departm ent contract .
3.Water and Material Management . After post -curing is completed, manage the curing water 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 proj ect location if this information is not provided in the contract documents.
a.Handling of curing water used in a styrene based thermoset resin liner installation:
1.Collect and transport curing water from the site for reuse within another CIPP location; and/or
2.Collect the water and dispose or treat at off site facilities. Transport wastewaters 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 ac cept 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
3.Treat wastewater on -site to acceptable styrene and thermal loading and discharge to receiving waters in accordance with agreements received from the Regional NYSDEC
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Section 600 STANDARD SPECIFICATIONS (USC) January 1, 202 4 VOLUME 3 Office.
b.For curing water from non -styrene based processes, collect water for disposal off -site as 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.
c.Collect any excess resin and any curing materials at the upstream and downstream ends of the installation for disposal.
d.Record and document quantities of curing water removed from the site. Provide 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 th e 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 D irector, Materials Bureau.
4.Workmanship / Damage / Defects. The finished pipe liner shall be continuous over the entire 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 l iner 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.
5.Storm Drain Lateral Connections. Reconnect the existing storm drain lateral connections after the liner has been cured in place. Use robotic cutting devices to reestablish tie -ins in non - man accessible pipes.
E.Lining with a new Liner Pipe -General. Before lining, pull or push a single piece of liner pipe 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 identifi ed voids. Depending on the location and size of the voids, 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
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Section 600 STANDARD SPECIFICATIONS (USC) January 1, 202 4 VOLUME 3 additional cost to the state. Grout that fills invert and connected voids is covered in the cost for these items.
1.Lining with High Density Polyethylene Pipe. Prior to lining, follow in its entirety all 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 s ections 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.
2.Lining with Polyvinyl Chloride Pipe. Prior to lining, follow in its entirety all provisions of §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 thro ugh 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 lin er’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.
3.Lining with Corrugated Metal Pipe. Reline with Polymer Coated Corrugated Steel Pipe. 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 alignmen t 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 separatio ns 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 n ot obstruct with any bracing material the flow of grout into the annular space. Remove the bracing, struts and bands upon completion of this work.
4.Lining with Corrugated Steel Structural Plate Pipe and Pipe Arches with PCC Paved Invert . 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 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
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Section 600 STANDARD SPECIFICATIONS (USC) January 1, 202 4 VOLUME 3 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.
5.Lining with Steel Tunnel Liner Plate. Prior to lining, follow in its entirety all provisions of §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, inclu ding 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.
6.Lining with Structural Steel Plate. Prior to lining, follow all provisions of §602 -3.02 E. Lining 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 a re 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 in stallation. 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
602-3.03 Damaged 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 Damag ed Pipe and Repair.
602-4 Method of Measurement
602-4.01 Lining with new pipe. This work will be measured as the number of feet along the bottom
centerline, measured to the nearest foot.
602-4.02 Paving 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.
602-4.03 Shotcreting. 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 foo t.
602-5 BASIS 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. 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
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Section 600 STANDARD SPECIFICATIONS (USC) January 1, 202 4 VOLUME 3 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 602.550102 Lining with Steel Tunnel Liner Plate 8ga Square Feet 602.550103 Lining with Steel Tunnel Liner Plate 7ga Square Feet 602.550104 Lining with Steel Tunnel Liner Plate 5ga Square Feet 602.550105 Lining with Steel Tunnel Liner Plate 3ga Square Feet 602.75xx Lining with Polymer Coated CSP 12ga, (2 - 2/3”x1/2”) Feet 602.80xx Lining with Polymer Coated CSP 12ga, (3”x1”) or (5”x1”) Feet Refer to Contract Proposal for full Item Number and full description. SECTION 603 - CULVERTS AND STORM DRAINS
603-1 DESCRIPTION. Construct culverts and storm drains in accordance with these specifications, the
contract plans, and the appropriate standard sheets.
603-2 Materials
603-2.01 General. Materials requirements are specified in the following subsections:
Geotextile 207 Corrugated Structural Steel Plate for Pipe, Portland Cement Concrete 501 Pipe-Arches and Underpasses 707-09 Portland Cement 701-01 Galvanized Steel End Sections 707-10 Masonry Cement 701-02 Aluminum End Sections 707-11 Concrete Repair Material 701-04 Corrugated Aluminum Pipe 707-13 Concrete Repair Material – Corrugated Aluminum Structural
Source: New York Standard Specifications, 2024 Edition. Pages 478–484 of 1,264.