00414.00 358 Section 00414 - Pipe Renewal - Spray Applied Pipe Structural Liner
Description
00414.00Scope - This Work consists of lining existing pipes with a spray applied pipe structural liner
00414.01Submittals - Submit the following at least 10 Calendar Days before the preconstruction
conference:
Certification by the lining system manufacturer that the installer is licensed and certified as competent to perform the Work. Documentation showing the installer m eets the qualifications listed in 00414.30, and a list of the qualified personnel who are assigned to Work on this Project. Certification that manufacturing processes operate under a quality management system according to recognized industry standards. Manufacturer's technical data showing complete information on material composition and physical properties. Include manufacturer's recommendation for handling, storage, installation, curing, finishing, and for the repair of a damaged liner. Independent third party certification of test results confirming that the SAPL liner system meets the structure properties according to 00414.10. Field sampling and testing plan for physical properties according to 00414.10. Include the name and location of independent third party laboratory performing testing on the installed liner system. Provide certification that the independent third party laboratory has the appropriate accreditation for each specified tests to be performed. Contingency repair plan including methods and Equipment to be used to repair or replace unacceptable SAPL defects identified in 00414.72. Stamped design of the proposed liner according to 00150.35 and 00414.02.
00414.02Design Parameters - Use the following design parameters for a fully deteriorated gravity
pipe design: Condition Parameter Soil modulus of Reaction ..........2,000 psi maximum Load Conditions: Soil ................................120 lb/cf minimum Traffic .............................LRFD HL -93 live load Height of fill from invert ........................... * Groundwater Elevation above Invert ....... * Minimum Factor of Safety .........2.0
* Parameters will be listed in the Special Provisions. The minimum liner thickness, independent of design for all structural applications:
1.0 inch for all pipes less than 48 inches in diameter or equivalent. 1.5 inches for all pipes greater than 48 inches in diameter or equivalent.
00414.30 359 Materials
00414.10Liner Properties - Furnish a cementitious or geopolymer mortar Material that meets the
following minimum physical property requirements.
PropertyTest Method Duration Test Value Minimum Compressive Strength ASTM C109 1 Day 3,000 psi 28 Days 8,000 psi Minimum Flexural Strength ASTM C293 7 Days 850 psi 28 Days 1,100 psi Modulus of Elasticity ASTM C469 28 Days 3,600,000 psi Bond Strength ASTM C882 28 Days 2,000 psi Freeze Thaw Resistance ASTM C666 300 Cycles Min. 90%
00414.11Delivery and Storage - Deliver and store all product Materials according to the
manufacturer’s recommendations and accompanied by the material safety data sheets. Deliver all Materials in t he manufacturer’s original unopened packages. Check to ensure each package is labeled with the manufacturer’s brand name, batch number and expiration date. Do not use Material that has exceeded the expiration date, or Material from defective, punctured or damaged packages.
Equipment
00414.20Equipment - Use Equipment approved by the manufacturer to apply the SAPL and that
meets the following requirements:
reciprocating head.
runs out or overflows.
Material prior to pumping.
Labor
00414.30Personnel Qualifications - Provide installers who:
Are licensed, and certified by the manufacturer of the SAPL product to be used on the Project. Have at least 3 years of active experience in the spin cast installation of cementitious or geopolymer mortar liners. Have installed at least a cumulative of 5,000 feet of cementitious or geopolymer mortar by spin cast and hand application. or
Provide a manufacturer’s representative with at least five years’ experience with cementitious or geopolymer mortar SAPL. The Contractor is responsible to ensure the manufacturer’s representative is on-site during the installation. When the representative is not on-site, provide the telephone number the manufacturer’s representative, or alternate, who is available on a 24- hour basis throughout the Project duration to the Superintendent and the Engineer.
00414.40 360 Provide a supervisor for the cementitious or geopolymer mortar liner Material installation who is assigned to the Project full time during the pipe structural liner Work and has supervised at least 15,000 feet of cementitious or geopolymer mortar liner by spin cast and hand application.
Construction
00414.40General - Field verify pipe inside diameter(s) throughout the pipe, length(s), alignment,
Material and condition of the host pipe prior to ordering liner Material and construction.
00414.41Pipe Cleaning - Clean the pipe by removing all debris, sediment, and other accumulated
Material. Do not use chemicals without the written approval of the Engineer. Remove and di spose of all debris according to 00290.20.
00414.42Pre -Installation:
inspection of the pipe acc ording to 00415, at least 5 Calendar Days before beginning pipe lining Work.
a highly flowable lean concrete mix according to 00442. Seal all open joints with an approved hydraulic cement or geopolymer lining Material prior to the lining of the pipe. Repair or restore the host pipe suitable for cementitious or geopolymer mortar lining as directed. Repairs will be paid for according to 00195.20 .
Seal all active water infiltration into the pipe prior to application of the SAPL by applying quick - setting mortars or chemical grouts approved by the Engineer.
When requested by the Engineer, perform a new or supplemental pre-construction video inspection of the pipe accor ding to Section 00415 after the repairs have been completed.
00414.43Installation - Install the SAPL according to the manufacturer's recommendations and
control the temperature and humidity. The SAPL shall be smooth, uniform and free of any defects.
thickness per Pass is 1/2 inch and the m aximum uniform thickness is 3/4 inches per Pass. During installation ensure the corrugation troughs are completely filled. Plastic indicator tabs may be attached on the Structure to verify the design thickness is achieved. Position the tabs height just below the specified liner thickness. Verify Material thickness at three various random locations around the pipe perimeter a minimum of once every 10 linear feet along the pipe profile. Measure the Material thickness over the corrugation crests using a depth gauge. Ensure the Material thickness over projecting bolts on structural plate culverts is a minimum of 1/2 inch. Apply additional Material at locati ons less than the design thickness using the rotating applicator head.
recommendations.
00414.73 361 (c) General - Submit a daily written report of:
Time, calibration and rate of travel of the applicator to achieve the specified design thickness. Verified Material thickness according to 00414.43(a). The outside ambient air temperature and the temperature and humidity inside the host pipe.
Finishing, Cleaning Up, and Testing
00414.70General - Ensure the cured cementitious or geopolymer mortar is continuous and free as
from visual defects such as foreign inclusions, delamination, and cracking at any location. Verify the SAPL is impervious and free of any leakage fr om water infiltration or ex filtration from the lined pipe.
Remove temporary dams or filtration measures after Work is complete and pipe is clean and restored.
00414.71Post Installation Video - After installation of the applied Material perform a
post-installation video inspection of the pipe according to Section 00415.
00414.72Material Sampling and Testing :
construction, for a total of four samples. Additionals amples during the application may be taken at the request of the Engineer. Employ an independent third party ACI certified testing agency to properly obtain and transport the test samples and perfor m Material testing according to 00414.10. Individually l abel and log each sample with the following information:
Project Name Name of Contractor Sampler’s name Product batch number(s) Sample number Liner installation date Date and time of sample Location of sample within culvert Name and location of third party laboratory
positions at established intervals through the pipe at no additional expense to the Agency. The measurement of the ac tual liner thickness will equal the average core thickness of all core samples taken. Repair the core holes in the pipe liner according to the manufacturer’s recommendations at no additional cost to the Agency.
00414.73Repairs - Repair defective areas to meet the requirements of the Plans and Specifications
Before making repairs, provide the manufacturer's recommendations for liner repairs, subject to approval by the Engineer. Repair or replace liners that have:
Installed thickness less than 90 percent of the specified design thickness. 28 Day compressive strength less than 8,000 psi, as determined by ASTM C109 . 28 Day minimum flexural strength less than 1,100 psi as determined by ASTM C293. Infiltration or exfiltration of water through the liner. 00414.75 362 Cracks larger than 0.032 inches wide. Separation of the liner from the host pipe.
If repairs are necessary perform an additional post -installation video inspection of the repaired areas of the pipe according to Section 00415.
00414.75Contractor Warranty - The Contractor unconditionally warrants to the Agency the product
and installation under this Section against failure, according to this Subsection and 00170.85(b)(1).
"Unconditionally warrant" means that the warranty covers all failures, regardless of the source or cause of the failure, including, without limitation, whether the source or cause is or may be related to workmanship, inspection, or choice of Materials.
The Agency inspection of any portion of the Work during the Contract and during t he product installation, the Agency acceptance of the Work, corrections under the warranty, or expiration of the warranty shall not relieve the obligations under this warranty.
Infiltration or exfiltration of water through the liner. Cracks larger than 0.032 inches wide. Separation of the liner from the host pipe.
remedy at no additional cost to the Agency:
Provide a liner repair plan and written timeline of when the Work will be completed within 10 Calendar Days of the Agency’s writ ten notification of failure. One of the following, as approved: • Remove the failed liner and install a full -thickness liner, • Construct a full pipe replacement, or • Install a liner repair. Complete one of the approved remedy’s within 60 Calendar Days of the Agency's written notification of failure. Use Materials and procedures meeting the Specifications. Coordinate timing of repair Work with the Engineer.
cause a hazard, the failure may be temporarily corrected by Agency or other forces at no additional cost to the Agency. Replace temporary repairs with permanent repairs at no additional cost to the Agency and according to the Specifications and within the time specified in 00414.75(c).
Measurement
00414.80Measurement - The quantities of installed spray applied pipe structural liner will be
measured on the length basis. The length will be measured, with no deduction for Structures or fittings, along the pi pe flow line from center to center of manholes, inlets, Structures, special sections, or the ends of pipe, whichever is applicable.
00414.90 363 Payment
00414.90Payment - The accepted quantities of Work performed under this Section will be paid for
at the Contract unit price, per unit of measurement, for the following items: Pay Item Unit of Measurement
In item (a), the nominal size of the host pipe will be inserted in the blank.
Payment will be payment in full for furnishing and placing all Materials, and for furnishing all Equipment, labor, and Incidentals necessary to complete the Work as specified.