GENERAL SPECIFICATIONS AND GUIDELINES FOR INSTALLATION MASTERLINER CURED-IN-PLACE PIPE SYSTEMS

Transcription

1 GENERAL SPECIFICATIONS AND GUIDELINES FOR INSTALLATION OF MASTERLINER CURED-IN-PLACE PIPE SYSTEMS 34

2 TABLE OF CONTENTS 1.00 INTRODUCTION 2.00 SITE WORK PREPARATIONS 3.00 THE PRODUCT AND COMPONENT MATERIALS 4.00 TECHNICAL SPECIFICATIONS 5.00 MASTERLINER DESIGN AND SELECTION 6.00 INSTALLATION; PULL IN PLACE WATER INVERSION AIR INVERSION 7.00 PAYMENT 8.00 GENERAL INFORMATION AND WARRANTY 35

3 GUIDELINES AND GENERAL SPECIFICATIONS FOR INSTALLATION OF MASTERLINER CURED IN PLACE PIPE LINING SYSTEMS. 1.0 INTRODUCTION: MASTERLINER CIPP systems are the only available complete encapsulating pipeline rehabilitation process. MASTERLINER has been formed for the sole purpose of developing, manufacturing, distributing and training installers on the use of its proprietary MASTERLINER cured in place pipeline rehabilitation system. The MASTERLINER process has been involved in an extensive 24 month Research and Development program to design a user-friendly, first class NO-DIG pipe lining system INSTALLATION INTRODUCTION: The MASTERLINER CIPP tube combines proprietary equipment and engineering design technology with unique installation techniques to solve the numerous problems encountered when installing a no-dig pipeline rehabilitation process. Utilizing the latest state of the art tools and techniques, sound engineering, and experienced field installation personnel, what you end up with is a quality assured finished product. The liner will be impregnated with a thermal setting resin that will completely wet out the soft flexible absorbent tube. The impregnated liner can now easily be transported to the job site. Curing is accomplished by circulating air and steam to cross-link the customized resin into a hard, impermeable pipe. When cured, the hardened liner will extend from manhole to manhole in a continuous tight fitting watertight pipe-within a pipe, chemically resistant to sewage gases and materials. Where specified, this system can be used in sanitary sewers, storm drains, house connections and manholes. With the assistance of a low powered two-ton standard winch, large diameter liners can be installed easily. ONLY MANUFACTURER CERTIFIED CONTRACTORS WILL BE ALLOWED TO INSTALL MASTERLINER CURED IN PLACE LINER PIPE. 36

4 1.02 INTENTION: The intent of this CIPP lining process is to line pipes which are subject to partial structural deterioration, partial distortion, interior corrosion, settling, misalignment, cracking, ex-filtration and infiltration. The liner will withstand long-term external hydrostatic loading SITE WORK AND PREPARATIONS 2.01 TELEVISION INSPECTION PRIOR TO INSTALLATION: The contractor is advised that a video tape inspection was made of the pipeline to be reconstructed and that this tape is available for review prior to bid opening. All prospective bidders are urged to view the tapes. The contractor will also be required to perform another television inspection and video tape recording of the pipeline a maximum of seven (7) days prior to the setting up of the liner insertion equipment at the job site. This inspection will be performed utilizing a radial eye camera, to determine the latest condition of the pipeline and to accurately identify the location of the active service connections. Should the result of this television inspection show a condition different than previously noted, the contractor shall immediately notify the Engineer CLEANING: The contractor shall furnish all labor, materials and equipment and shall do all necessary work to remove and dispose of all debris, silt, protruding service connections and roots in the existing pipeline and manholes FLOW BYPASSING: The contractor shall provide for the diversion of flow at an existing upstream manhole (if available) and pump the flow into an existing downstream manhole. The pump and bypass lines shall be of adequate capacity and size to handle the flow. The proposed bypassing system shall be submitted to the engineer for approval and no work shall commence until such approval is granted OBSTRUCTION REMOVAL: A high speed rotation hydraulic cutter will be used to cut protruding service laterals, offset joints, roots, barnacles, concrete or other obstructions in V.C.P. (vitrified clay pipe), concrete pipe and C.I.P. (cast iron pipe). The cut will be made flush with the wall of the pipe to be restored, and the debris will be pushed down the pipe to the downstream manhole. If an obstruction cannot be removed by conventional methods or by remotely controlled mechanical equipment, then the contractor shall remove or repair the obstructions by excavation. Such excavation shall be considered as a separate pay time and must be approved prior to start up PRIOR TO COMMENCING WORK: The contractor will provide submittals on all lining materials and resins and shall furnish manufacturer certification that the liner material complies with the requirements of the customer. The contractor will provide pre-sizing calculations that demonstrate that the liner has been properly downsized to avoid the creation of wrinkles or folds SAFETY: The Contractor shall conform to all work safety requirements of pertinent regulatory agencies, and shall secure the site for the working condition in compliance with the same. The contractor shall erect such signs and other devices as are necessary for the safety of the work site. 37

5 The contractor shall also perform all of the work in accordance with applicable OSHA standards. Emphasis is placed upon the requirements for entering confined spaces and working with steam EXTENSION OF TIME: If the contractor is delayed in the course of the work by act or neglect of the client, municipality, or by unexpected problem beyond his control, or by any cause which the engineer shall decide justifies the delay, then the time of completion shall be extended for a reasonable time as agreed upon by the engineer and contractor LINER AND COMPONENT MATERIALS: 3.01 TUBING: The liner tube will consist of one or more layers of flexible needled felt or an equivalent woven or non-woven material GEO MEMBRANE: The needled felt will have a Geo membrane coated on either one or both sides width of a minimum thickness of 12 mils RESIN: A premium corrosion resistant isophthalic, thixotropic unsaturated polyester resin. The resin will be specifically formulated for the use in the manufacture of needled felt liners for insertion into sewer and drain lines needing repair CATALYST: The catalyst shall be compatible with the resin and the other materials used in the manufacturing of the CIPP. The non-promotes resin shall be catalyzed by the addition of a sufficient catalyst to produce the required physical properties of the cured in place pipe TECHNICAL SPECIFICATIONS: 4.01 FINISHED AND CURED LINER PROPERTIES: The material will be capable of carrying resin, be able to withstand installation pressure and curing temperatures, and the compatible with the resin system used. The resin system used will be compatible with the application and pipeline environment and shall be able to cure in the presence or absence of water. The fully cured-in-place liner will meet or exceed the minimum structural standards of the industry. Industry Specifications The CIPP shall conform to the minimal standards as follows: ASTM Rehabilitation of Existing Pipelines and Conduits by the Inversion and Curing of a Resin-Impregnated Tube. ASTM F Rehabilitation of Existing Pipelines and Conduits by Pulled-in-Place Installation of Cured-in-Place Thermosetting Resin Pipe(CIPP) 38

6 D-5813 Standard Specifications for Cured-In-Place Thermosetting Resin Sewer Pipe C-581 Standard Practice for Determining Chemical Resistance of Thermosetting Resins D-2990 Standard Test Methods for Tensile, Compressive, Flexural Creep, and Creep Rupture of Plastics. D-638 Test Method for Tensile Properties of Plastic. D-790 Test Method for Tensile Properties for Unreinforced and Reinforced Plastics and Electrical Insulating Materials. D-256 Impact Test. D-638 Barcol Hardness Test. MASTERLINER exceeds the minimum strength requirements demonstrated in the following ASTM standards: Tensile Yield: 3,000 psi D-638 Modulus of Elasticity: 300,000 psi D-790 Flexural Strength: 4,500 psi D-790 Flex Modulus of Elasticity: 250,000 psi D LINER DESIGN AND SELECTION The contractor shall furnish, prior to the use of the lining materials, satisfactory written guarantee of his compliance with MASTERLINER standards for all materials and techniques being used in the lining process. After the liner has been cured, the contractor will trim any excess liner in the manholes. He will then proceed to reconnect the existing active service connections. This is done without excavation by the use of an internal, remote controlled cutting devise through the newly installed liner RESIN AND TUBE ACCEPTANCE: At the time of resin impregnation, the entire MASTERLINER tube shall be inspected for defects. The resin shall not contain fillers, except those required for viscosity control, fire retardant, or extension of pot life. Thixotropic agents that do not interfere with visual inspection may be added for viscosity control. Resins may contain pigments, dyes, or colors, which do not interfere with visual inspection of the CIPP or its required properties. Additives may be incorporated that enhance the physical and/or chemical resistance. The impregnated liner bag shall be transported to and stored at the site in such a manner that it will not be damaged, exposed to direct sunlight, or result in any danger to public safety. 39

7 5.02 INSPECTION: The contractor shall arrange a freely accessible place and means so that the MASTERLINER pipe and all equipment to be used during the installation, including injection manifolds, gauge stations, steam equipment, winches, etc., can be inspected by the client. The contractor shall prepare and inspect all necessary equipment for the installation prior to going to the job site. The contractor shall also provide all necessary tools and spare parts as may be required for the most frequently damaged equipment, and shall make sure that said tools and spare parts are available at the site. The supporting equipment such as pumps and generators must be provided at the site in the event there is a fluid surge and pumping is required on an emergency basis. The contractor shall also prepare and make operable all necessary communication equipment for his field crew INSPECTION OF LINER: The contractor shall designate a location where the un-cured resin in the original containers and the un-impregnated liner will be impregnated prior to installation. The contractor shall allow the engineer and/or his representative to inspect the materials and chemical impregnation procedure. The quantities of the liquid thermal-setting materials shall be as per manufacturer's standards to provide the lining thickness specified. The impregnated liner material shall be inserted through the existing manhole by means of a winch assembly. If the surface is sufficiently rough to cause damage to the impregnated liner material a protector shield may be used to cover the manhole opening and the invert throughout the section to be lined. Next, the impregnated MASTERLINER shall be inserted into the existing sewer by a cable attached to the liner to be pulled by a winch INSTALLATION, PULL IN PLACE, WATER INVERSION AND AIR INVERSION: 6.01 PULL IN PLACE: The liner may be drawn into the existing sewer by means of winch cable. With the ends of the liner sealed, the liner will be expanded by compressed air or water. The pulling tension shall not exceed more than half of the tensile strength of the liner AIR INFLATION: Initially, compressed air is introduced, inflating and forming the liner material against the inner walls of the pipe to be lined STEAM AND AIR CURING: After the inflation steps are completed, the contractor shall begin the curing process by utilizing the MASTERLINER approved heat source. The equipment will be capable of delivering steam to the far end of the liner to uniformly raise the temperature required to effectively cure the resin. The temperature maintained during the curing period shall be that recommended by the resin manufacturer and approved by the engineer. During the curing process the heat source shall be fitted with pressure gauges and thermocouples to continuously monitoring the temperature of the incoming and outgoing heat medium supply. The water, steam or air temperature during the cure period shall meet the resin manufacturer's requirements as measured at the heat source inflow and outflow return lines. 40

8 At the engineer's direction, the contractor shall provide standby equipment to maintain the heat source supply throughout the curing process, and the contractor shall maintain static head (internal pressure) in the liner greater than the maximum design external water pressure. The initial cure shall be deemed complete when inspection shows that the exposed liner portions appear hard and sound and the remote temperature sensors indicate that an exothermic reaction has occurred. The cure period shall be of duration recommended by the resin manufacturer as modified to account for length, thickness and diameter of the liner. The hardened liner has to be cooled to a temperature below 100 degrees F. After reaching the appropriate temperature, the static head in the lined pipe is relieved. This cool-down period shall occur prior to opening the downstream stopper, reconnecting of services and returning normal flow back into the system. If the cured pipe does not fit tightly against the host pipe at its termination point(s), the voids shall be sealed, by filling them with a resin mixture compatible with the CIPP. All internal (dry or non-bonded) inflation tubes that are not bonded to the resin impregnated tube prior to installation of the liner tube shall be completely removed from the finished cured-in place liner pipe. Wrinkles in the finished liner pipe that cause a backwater, reduce the pipe's hydraulic capacity or structural stability or that create voids between the liner and pipe wall will be unacceptable. All unacceptable sections shall be removed or repaired by a method approved by the engineer at the contractor's expense. Repair methods shall be proposed by the contractor and submitted to the engineer for approval WATER INVERSION: The wet-out tube shall be inserted through an existing manhole or other approved access by means of an inversion process using water with a hydrostatic head sufficient to fully extend it to the next designated manhole or termination point. The tube shall be inserted in the vertical inversion standpipe so that a leak proof seal is created. The inversion head shall be adjusted to sufficient height to cause the impregnated tube to invert from point of termination and hold the tube tight to the pipe wall, producing dimples at side connections. Care shall be taken during the inversion so as not to over-stress the felt fiber HEATED WATER CURING: If heated water is used to cure the liner, provide a suitable head source, and water recirculation equipment capable of delivering hot water to the far end of the liner to quickly and uniformly raise the water temperature in the entire inverted liner to the temperature to commence the exothermic reaction of the resin as determined by the catalyst system employed. The heat source shall be fitted with suitable monitors to gauge the temperatures of the incoming and outgoing water supply to determine when uniform temperature is achieved throughout the length of the liner. Water in the liner shall be raised to a temperature recommended by the resin manufacturer. Initial cure is deemed to be complete when the uniform temperature recommended by the resin manufacturer is achieved throughout the length of the liner. Water temperature monitors at the heat source shall determine this uniform temperature. The post cured period shall then commence with the heat source shut down with recirculation of the water continued to maintain 41

9 uniform temperature in the liner. Hot water may be bled out of the system and replaced by clean water at ambient water main temperature to control post cure water complete cure. Time required to cure is a function of the pipeline section diameter and length, and shall be determined by the lining manufacturer's instructions. The curing process should be sufficient to hold the liner tight to the pipe wall and produce dimples at side connections. After curing, open and drain the line in a manner so a vacuum will not be developed which may damage the installed liner AIR INVERSION: Insert the wet-out tube through an existing manhole or other approved access by means of an inversion process using an application of air pressure sufficient to fully extend it to the next designated manhole or termination point. The tube shall be connected by an attachment at the upper end of the guide chute so that a leakproof seal is created with the impermeable plastic membranes side facing out. As the tube enters the guide chute, the tube shall be turned inside out. The inversion air pressure shall be adjusted so that sufficient pressure is provided to cause the impregnated tube to invert from point of termination and hold the tube tight to the pipe wall, producing dimples at side connections. Care shall be taken during the inversion so as not to over stress the woven and non-woven materials HOT AIR: If hot air is used to cure the liner, provide suitable heat source and recirculation equipment to uniformly distribute the heat. The temperature and pressure in the line during the cure period shall be that recommended by the resin manufacturer. Hot air generating equipment shall be equipment with a suitable monitor to gauge the temperature of the outgoing steam. The temperature of the resin being cured shall be monitored by placing gauges between the impregnated tube and the existing pipe at both ends during cure. Initial cure shall begin during temperature heat-up and shall be deemed complete when exposed portions of the new liner appear to be hard and sound and the remote temperature sensor indicate that the temperature is of a magnitude to create an exotherm or cure in the resin. After initial cure is reached, the temperature shall be raised to the post cure temperature recommended by the resin manufacturer. Post cure temperature shall be held for a period as recommended by the resin manufacturer. During the post cure time the distribution and control of hot air shall continue to maintain required temperature. The curing process should be sufficient to hold the liner tight to the wall and produce dimples at side connections. Curing of the liner pipe shall take into account the existing pipe material and size, the resin system and ground conditions, which includes temperature, moisture level and thermal conductivity of soil SERVICE CONNECTIONS: After the curing is complete and the pipe system is placed into service, all active house connection sewers shall be reinstated without delay. This is to be done without excavation by use of an internal, remote-controlled cutting device through either the lateral pipe or through the newly installed liner TELEVISION INSPECTION AFTER INSTALLATION: A television inspection and video tape recording of the newly lined pipe including the restored service connections shall be performed immediately after work is completed. Should the results of this inspection reveal any defects as defined above, the contractor will be required to repair or replace these defects as ordered by the engineer at the sole cost of the contractor. 42

10 The contractor shall furnish and maintain in good condition, all equipment necessary for the proper execution and inspection of the work PAYMENT: Payment of rehabilitation work will be based on the unit price listed in the bid schedule. This payment shall include full compensation for all labor, material, tools, and incidentals for lining of the existing pipeline Payment for reinstallations of house connection shall be in accordance with bid item. Payment for obstruction removal by a point repair shall be in accordance with bid item MEASUREMENTS FOR PAYMENT: All measurements shall be as specified or made by conventional means with accuracy consistent with field conditions and common practice. Should a discrepancy in measurement exist which is greater than 10%, the item in question shall be re-measured by both the contractor and the owner's representative for verification MEASUREMENT FOR PAYMENT SHALL BE BASED ON THE FOLLOWING SCHEDULE: PIPELINE CLEANING shall be paid for at the unit price bid per linear foot of each size pipe. Measurement of the actual number of feet cleaned shall be made from the center of the manholes. TELEVISION INSPECTION of the sewer lines shall be paid for at the unit price bid per linear foot of each size pipe. Measurements of the actual number of feet inspected shall be made from the center of the manholes. PUMPING AND BYPASSING of sewer flows shall be paid for at the unit price bid per setup. REMOVAL OF INTRUDING PIPES shall be paid for at the unit price bid per removal. INSTALLATION OF LINER shall be paid for at the unit price bid per foot of liner installed for each size pipe. REINSTATEMENT OF SERVICE CONNECTIONS shall be paid for at the unit price bid per reinstatement. FINAL TV INSPECTION shall be paid for at the unit price bid per linear foot of each size pipe. Measurement of the actual number of feet inspected shall be made from the center of the manholes. 43

11 7.03 CLEANUP: After the liner installation has been completed and accepted, the contractor shall clean up the entire project area. The contractor, in accordance with local laws and regulations shall dispose of all excess materials and debris, not incorporated into the permanent installation GENERAL INFORMATION AND WARRANTY THIRD PARTY TEST DATA: Performance quality is assured through stringent in house and third party testing. Tulane University's ASTM lab, established in 1909, has conducted a series of tests on the MASTERLINER PRODUCT. All of the test results prove that the MASTERLINER product is at least equal or superior to the competition. These industry standard tests were conducted to insure quality control: 1. Tensile Strength TEST per ASTM D Flexural Strength Test per ASTM D Impact Test per ASTM D Barcol Hardness Test per ASTM D

12 The randomly picked samples were subjected to a tensile and flexural load using Instron Universal Testing equipment ADVANTAGES TO THE MASTERLINER CURED IN PLACE PIPE SYSTEM: There are many advantages to MASTERLINER'S total encapsulating program: * NO EXCAVATION * FAST AND SIMPLE INSTALLATION * HIGH STRENGTH AND CORROSION RESISTANT VINYL OR POLYESTER RESINS * SUBSTANTIAL COST SAVINGS * JOINT-LESS RENOVATION * CUSTOM PIPE DIAMETERS AND WALL THICKNESSES * IMPROVED FLOW CHARACTERISTICS * VIRTUALLY ELIMINATED INFILTRATION & EXFILTRATION * CONTINUOUS RESEARCH AND DEVELOPMENT QUALITY ASSURANCE The MASTERLINER product can also line service connections & structurally reinforce manholes. MASTERLINER CAN TURN A LEAKING PIPE INTO NEW, STRONG, LEAK-PROOF SYSTEM IN JUST HOURS. MASTERLINER IS THE SUPERIOR CURED-IN-PLACE PIPELINE REHABILITATION SYSTEM WARRANTY: The contractor shall warrant the liner installation for a period of one year. During the warranty period, any defects that affect the integrity or strength of the pipe shall be repaired at the contractor's expense in a manner mutually agreed upon by the owner and the contractor. OUR MISSION WE WILL CONTRIBUTE TO OUR CUSTOMERS' SUCCESS BY PROVIDING EXCEPTIONAL QUALITY PIPE LINING PRODUCTS. WE WILL ACHIEVE AN UNSURPASSED LEVEL OF CUSTOMER SATISFACTION BY PROVIDING FLEXIBLE AND EFFICIENT SERVICE. FOR FURTHER INFORMATION OR THE NAME OF THE QUALIFIED MASTERLINER LICENSED CONTRACTOR IN YOUR AREA CONTACT: 45