EI- MH TO MH LINER

Transcription

1 EI- MH TO MH LINER TABLE OF CONTENTS PART ONE: PROJECT-SPECIFIC CONDITIONS 101 PROJECT DESCRIPTION 102 SCOPE OF WORK 103 ESTIMATED FLOWS 104 PROJECT SCHEDULE 105 HIGH WATER USERS PART TWO: STANDARD MMSD CURED-IN-PLACE PIPE (CIPP) LINING SPECIFICATIONS 201 REFERENCED DOCUMENTS 202 PREQUALICATION OF BIDDERS 203 GENERAL REQUIREMENTS OF CONTRACTOR (1) SUBMITTALS (2) CONTRACTOR S INSURANCE (3) SAFETY (4) CLEANING OF SEWER LINES (5) INSPECTION OF PIPELINES (6) LINE OBSTRUCTIONS (7) BYPASSING PUMPING / DIVERSION (8) HIGH FLOW SERVICE LATERAL CONSIDERATIONS (9) WATER FOR CLEANING, FLUSHING AND INVERSION (10) PUBLIC NOTIFICATION (11) TRAFFIC CONTROL (12) USE OF SITE (13) CLEAN-UP (14) LIQUIDATED DAMAGES (15) MAINTENANCE RETAINER 204 CURED-IN-PLACE LINER (1) MATERIALS (2) TESTING REQUIREMENTS (3) CIPP INSTALLATION (4) SEALING LINER AT MANHOLES (5) REINSTATEMENT OF SERVICE CONNECTIONS (6) CHEMICAL GROUTING OF SERVICE CONNECTIONS (6) INSPECTION & TESTING

2 PART ONE: PROJECT-SPECIFIC CONDITIONS SECTION 101 PROJECT DESCRIPTION This Specification covers the work necessary to furnish and install complete, the cured-in-place pipe (CIPP) for the East Interceptor MH to MH Liner. The CONTRACTOR shall provide all materials, labor, equipment, and services necessary for bypass pumping and/or diversion of sewage flows (including specified flows from private laterals), cleaning and television inspection of sewer to be lined, liner installation, reconnection of service connections, grouting and sealing of all service connections, and final television inspection of lined interceptor. SECTION 102 SCOPE OF WORK The table below provides a summary of the estimated section lengths, pipe size and type and total pipe length. Pipe sizes, lengths, and number of service connections are all estimated values. The CONTRACTOR shall field verify these quantities. The distances are taken from the sewer book maps which list the distance from center of one manhole to the center of the next. Section Pipe Dia. / Type / Year LF (est.) # of Service Connections to be Reinstated (estimated) MH to MH / CI / MH to MH / VCP / MH to MH / VCP / MH to MH / VCP / Total Estimated LF = 1339 (90 LF of 14 Liner and 1249 LF of 15 Liner) Total Estimated Service Connections to be Reinstated = 14 The following are approximate manhole depths (rim to invert). Contractor shall field verify MH DEPTH MH DEPTH MH DEPTH Rehabilitation of the sanitary sewer shall be without excavation by the installation of a resin-impregnated flexible tube, which is tightly formed to the original pipe. The resin shall be cured using hot water under hydrostatic pressure, pressurized steam within the tube, or by an ultraviolet light train within the pipe. The Cured-in-Place Pipe (CIPP) shall be continuous and tight fitting. All service connections to buildings shall be reinstated without excavation, utilizing a remote controlled cutting device, monitored by a video TV camera. The contractor will also provide cleaning and televising of the siphon between MH and MH This will be completed while bypassing measures are in place so that the siphon can be completely pumped out and then cleaned and televised without flow or standing water in the pipe. A detail of the existing siphon can be found in the contract drawings. The specific pipe sections that are included in the scope of this contract are shown on the accompanying maps. In 2010, MMSD televised all sections of pipe that are proposed for lining. Televising reports are included in the back of this specification. DVD copies of the televising tapes are available upon request. S-2

3 SECTION 103 ESTIMATED FLOWS The table below provides a summary of the estimated peak and average daily flows in each section. The flow in the sewers varies greatly depending upon time of day. The estimated flows, as taken from the 2009 MMSD Collection System Evaluation, in the East Interceptor are detailed in the following table: Upstream MH ESTIMATED FLOWS (2010 UF) Peak Daily Downstream MH (MGD) Average Daily (MGD) A Bypass pumps shall be sized to handle a peak flow of 1.5 MGD (approximately 1042 GPM). SECTION 104 PROJECT SCHEDULE Submittals, shop drawings, televising & cleaning the pipe, and material delivery shall be performed prior to the start of construction. Start of construction shall be Monday September 19, Substantial completion (liner installed, sealing of liner at manholes, and reinstatement of service connections) shall be Friday, December 30, Final completion shall be Friday, January 20, The delay between start of construction and substantial completion is to allow for flexibility of schedule. It is not anticipated that the work will take as long as this time span allows for. SECTION 105 HIGH FLOW SERVICE LATERALS Section 203(8) of these specifications describes the requirements of the Contractor regarding high flow service laterals. The high flow service laterals for this project are detailed in the following table: HIGH FLOW SERVICE LATERALS Address Property Description 44 S. Fair Oaks Ave. Restaurant 3314 Thorp St. Apartment Complex 21 S. Fair Oaks Ave. Car Wash S-3

4 PART TWO: MMSD STANDARD CURED-IN-PLACE-PIPE (CIPP) LINER SPECIFICATIONS SECTION 201 REFERENCED DOCUMENTS This specification references standards from the American Society for Testing and Materials, such as: ASTM F1216 (Rehabilitation of Existing Pipelines and Conduits by the Inversion and Curing of a Resin-Impregnated Tube), ASTM F1743 (Rehabilitation of Existing Pipelines and Conduits by Pulled-in-Place Installation of Cured-in-Place Thermosetting Resin Pipe), ASTM D543 (Test Method for Resistance of Plastics to Chemical Reagents), ASTM 638 (Test Method for Tensile Properties of Un-reinforced and Reinforced Plastics and Insulating Materials), ASTM D790 (Test Methods for Flexural Properties of Un-reinforced and Reinforced Plastics and Electrical Insulating Materials), and ASTM F0219 (Rehabilitation of Existing Pipelines and Conduits by the Pulled in Place Installation of Glass Reinforced Plastic) which are made a part hereof by such reference and shall be the latest edition and revision thereof. In case of conflicting requirements between this specification and these referenced documents, this specification will govern. SECTION 202 PREQUALIFICATION OF BIDDERS All Contractors seeking to become pre-qualified for this type of work must provide written documentation that their personnel have adequate experience and training in the installation of CIPP and that the product to be used is commercially acceptable and meets all requirements of this specification. For the product acceptability, it must have a minimum of 150,000 of successful waste water collection system installations in the USA. For the installer to be qualified, they must have at least 3 years of active experience in the commercial installation of the product. The installer must have successfully installed at least 15,000 of the largest diameter or larger pipe liner of the proposed product. All prequalification documentation shall be submitted per the requirements in the Advertisement For Bids. MMSD reserves the right to reject the bid of any bidder who cannot meet the minimum requirements set forth in this section. SECTION 203 GENERAL REQUIREMENTS OF CONTRACTOR (1) SUBMITTALS The Contractor shall submit the following for review and approval to the MMSD Engineer. a) Product Data b) Digital Video i) Submit manufacturer s product literature and application, installation requirements, and recommended repair requirements (patching) for materials used in liner. ii) Submit manufacturer s product certification of conformance to ASTM standards for materials used in liner. iii) Manufacturer s Wet Out Report including raw resin data for each liner to be installed and the Manufacturer s recommended curing procedure (to be delivered to site). iv) Submit two (2) copies of Liner Pipe Thickness Design Calculations. v) Submittals required in Section 205(2). vi) Results of tests specified in Section 205(7). i) Submit digital video of pipes in pre-lining condition. ii) Submit digital video of pipes in post-lining condition with no flow (i.e. so the future postlined pipe is visible) and showing reinstated and grouted (if applicable) service connections. c) Traffic Control Plan i) Submit Traffic Control Plan to MMSD Engineer a minimum of one (1) week prior to the start of work. All traffic control, including signing and barricading of the work areas, shall S-4

5 be the Contractor s responsibility and shall conform with the Federal Highway Administration s "Manual on Uniform Traffic Control Devices". ii) The Contractor shall be responsible for obtaining and paying all fees for any permits required by the City in addition to this submittal to MMSD. d) Construction Plan i) Submit Construction Plan detailing access routes, proposed storage areas, and proposed liner insertion points as required by Section 204(12) of these Specifications. Submit construction plan to MMSD Engineer a minimum of one (1) week prior to the start of work. ii) Submit bypass pumping plan, including: list of equipment, primary and backup pump sizes, estimated length of time required for bypassing, and planned pump suction and discharge locations. (2) CONTRACTOR S INSURANCE The contractor is required to obtain insurance as specified in Section 201 of the General Conditions with the exception of item e. Builders Risk Insurance. Builder s risk insurance is not required for this project. (3) SAFETY The contractor agrees to perform all work under this contract in accordance with local, state, and federal safety regulation. This includes, but is not limited to, evaluation of the atmosphere to determine the presence of toxic or flammable vapors or lack of oxygen prior to entering the manholes. (4) CLEANING OF SEWER LINES a) It shall be the responsibility of the Contractor to completely clean sanitary sewer prior to lining. The work shall consist of providing all labor, materials, power, utilities and equipment necessary to thoroughly clean identified sewers and restore them to 95% of their original carrying capacity. b) It shall be the responsibility of the Contractor to remove all internal debris, hanging gaskets and root intrusions from the sewer line. All debris must be removed from the pipe and is not permitted to flow downstream. If any debris is passed downstream, the Contractor shall clean the affected section(s) of sewer main at no additional cost to the MMSD. c) It shall be the responsibility of the Contractor to make a qualified effort to remove mineral deposits from cast iron pipe. At minimum, the cleaning effort will consist of running a hydraulically operated root cutter and/or lumberjack (or equivalent) through the pipe. After the root cutter has passed through the pipe, the remaining debris will be cleaned out with a jetter and the debris will be removed from the sewer. d) If inspection reveals that an obstruction cannot be removed by conventional sewer cleaning equipment, the Contractor shall immediately notify the Project Engineer. The Project Engineer shall determine if the obstruction is able to be removed by sewer cleaning equipment and, if not, if the particular section of main shall be repaired by the MMSD or removed from the contract. In the event that the Engineer determines that a repair shall be made the contractor shall proceed with work on other sections of main and return to the obstructed main after the MMSD has completed necessary repair(s). No additional compensation shall be made to the Contractor as a result of any delays necessitated by such repairs. e) Post cleaning condition of the pipe is subject to review and approval of the Engineer. f) Sewer cleaning shall be conducted in accordance with "Recommended Specifications for Sewer Collection Rehabilitation," published by the National Association of Sewer Service Companies (NASSCO). S-5

6 g) The Contractor shall furnish water for cleaning and flushing the existing sewer pipe. h) The Contractor shall be responsible for disposing all of the debris removed from the pipeline at a licensed disposal facility. (5) INSPECTION OF PIPELINES a) It is the responsibility of the Contractor to inspect all sanitary sewer mains to be lined using closed circuit television. Experienced personnel trained in locating breaks, obstacles, and service connections by closed-circuit television shall perform inspection. The interior of the pipeline shall be carefully inspected to determine the location of any conditions that may prevent proper installation of the impregnated tube, such as protruding service taps, collapsed or crushed pipe, and reductions in the cross-sectional area. These conditions shall be noted so that they can be corrected. The Contractor shall immediately notify the Project Engineer of any conditions that prevent the proper installation of the CIPP. b) The Contractor shall utilize a closed-circuit television video system that is capable of capturing, producing, and recording color digital video of the sewer inspection. The Contractor shall provide color digital video for each sanitary segment designated by the project plans. The video system shall have the capability of transferring the color video to an MPEG digital format compatible with personal computers. c) All inspections shall follow the Pipeline Assment Certification Program (PACP) protocol as established by the National Association of Sewer Service Companies (NASSCO). d) A digital video and corresponding log of the conditions present in the pipe sections before installation of the liner shall be made and kept for later reference and delivery to the MMSD. The pipe sections shall also be televised after the liner has been installed (with no flow in the pipe and when the entire pipe is visible) and the services reinstated. Copies of the post lining digital videos and logs shall be provided to MMSD. e) Each digital video segment shall be named according to start structure number_end structure number.mpg format. The digital video shall document in a clear and continuous manner the condition of the sewer segment from the upstream structure to the downstream structure. No interruptions or missing segments shall be allowed unless noted in writing by the MMSD s Project Engineer. The MMSD will reject any digital video that has foggy or static conditions on it. The video shall display on a continuous basis the sanitary sewer pipe footage, continuous video footage along total length, the upstream and downstream manhole number for the sewer segment being televised, the sewer pipe diameter, and the date of televising. (6) LINE OBSTRUCTIONS a) It shall be the responsibility of the Contractor to clear the line of all obstructions such as solids, hanging gaskets, roots, dropped joints, protruding service connections, crushed or collapsed pipe, and reductions in the cross-sectional area that prevent the insertion of the lining. b) If inspection reveals an obstruction that cannot be removed by conventional sewer cleaning equipment, the Contractor shall immediately notify the Engineer. MMSD may make any spot repair excavations necessary to uncover and remove or repair such obstructions. Delays caused by these obstructions will be accounted for in the project schedule, and the Contractor shall not be due any additional monies for the delays. (7) BYPASSING PUMPING / DIVERSION a) The Contractor shall provide for the continuous flow of sewage around the sections of sewer line designated for lining. The bypass pumping system shall be in place and working before the sewer lining work begins. The sewer shall be returned to gravity flow at the end of each working day. Unattended bypass pumping is not allowed. S-6

7 b) Bypass pumping shall be limited to those hours that the contractor is performing the work for this project unless necessitated by an emergency beyond the Contractor s control. A representative of the Contractor must be on-site at all times that bypass pumping is in operation. c) If the Contractor elects to use bypass pumping as a means of sewerage control, the methods, equipment, type of hose, etc., shall be subject to approval of MMSD. Hoses crossing streets, driveways, parking areas, etc., are to be ramped over to prevent damage to the hoses. Bypass pumps shall be sized to handle the peak flow with one pump out of service. Contractor must always have a backup pump ready in case a pump fails. d) No spillage of wastewater to adjacent streets, lawns, etc., shall be tolerated. If any such spillage should occur, all construction operations shall cease and cleanup shall commence immediately and be completed to the satisfaction of the Engineer prior to the resumption of any construction operations. e) Prior to submitting a bid for this project the Contractor shall familiarize himself with the sanitary sewerage facilities in this area and develop an adequate bypassing plan. A written plan shall be submitted to MMSD for approval prior to the start of work. f) Bypassing will not be permitted in the event of excessively wet weather. MMSD reserves the right to determine when bypassing will or will not be allowable in wet weather. g) The City of Madison s James St. pumping station forcemain empties into MMSD MH The station is an ejector or pot type station and is maintained by MMSD. Contactor will be responsible for controlling this flow during liner installation between MH and MH If the contractor chooses to shut off the pumps in the pumping station for any period of time, the contractor shall provide wastewater hauler(s) equipped with booster pumps for wet well dewatering. Cycle length at this station depends on wastewater and infiltration flow and can fluctuate between 8 minutes and 30 minutes. The table below includes total month run times in hours, as well as the total annual run times, the max daily run times, average daily runtimes, average max daily runtime, and record max daily runtimes from 7/2010 to 7/2011. All pumps have a pumping rate of 100 gpm (gallons per minute). AVERAGE DAILY RUNTIMES MAXIMUM DAILY RUNTIMES Date Pump 1 Pump 2 Total Pump 1 Pump 2 Total Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul S-7

8 Runtime Flow Average Daily 2.8 hrs/day 694 gal/hr Average Maximum Daily 4.5 hrs/day 1131 gal/hr Record Maximum Daily 8.1 hrs/day 2025 gal/hr (8) HIGH FLOW SERVICE LATERAL CONSIDERATIONS a) The Contractor shall be responsible for assuring that high flow service laterals are sufficiently protected against damage from lateral backup during the lining process. This will require effort beyond simple notification of the users. It may entail the use of alternative work schedules, bypassing of the lateral via a cleanout or access structure, discontinuation of water service to the user, vactor removal of backed-up wastewater, or other method subject to approval by the Engineer. b) High flow laterals will be determined by the Engineer and will be identified on the project plans and in the project specifications. c) All work associated with this section of the specifications shall be considered incidental to the overall project. (9) WATER FOR CLEANING, FLUSHING AND INVERSION The Contractor shall furnish water for cleaning and flushing the existing sewer pipe and for installing the CIPP. The Contractor shall obtain permission from the City Water Utility to use any fire hydrants in the area to facilitate liner insertion. The Contractor shall notify the City prior to initiating cleaning and flushing operations, and shall coordinate his operations with the City Water Utility so as not to deplete the local water supply and pay for the water used. (10) PUBLIC NOTIFICATION a) The Contractor shall make every effort to maintain service usage throughout the duration of the project. In the event that a service needs to be taken out of service, the maximum amount of time allowed for the service interruption shall be 8 hours for any property served by the sewer. The Contractor shall implement a public notification program that shall, at a minimum, require the Contractor to be responsible for contacting the owner of each home or business connected to the sanitary sewer and informing them of the work to be conducted and the date, time, and length of the service interruption. The Contractor shall also provide the following: i) Written notice describing the work to be performed. The notice shall be delivered to each home or business three (3) days prior to the beginning of work being conducted on the pipe section. The notice shall also contain a local telephone number of the Contractor that property owners can use to discuss the project or any problems that arise during installation of the liner. ii) Personal meetings with any property owners whose service cannot be reinstated within the time referenced in the written notice. b) MMSD shall provide the Contractor with names and addresses of affected property owners within the project limits. c) The Contractor will coordinate protection of high flow laterals with the Engineer and property owners as described in section 203(8). S-8

9 (11) TRAFFIC CONTROL a) The Contractor shall prepare and implement a Traffic Control Plan, to facilitate installation of the liner. The Contractor shall be responsible for obtaining and paying all fees for any permits required from the City. All traffic control, including signing and barricading of work areas, shall conform with the Federal Highway Administration s "Manual on Uniform Traffic Control Devices." (12) USE OF SITE a) The Contractor is responsible for determining the suitability of access points to the interceptor. The Contractor shall submit access routes, proposed storage areas, and proposed liner insertion points. These access routes, any proposed storage areas, and insertion points must be approved by MMSD before beginning work. b) Operation of construction vehicles or equipment, storage of materials, and insertion of liner shall not be allowed on private properties unless Contractor obtains written permission from private property owner. Contractor shall notify MMSD of intent to contact private property owner for the purpose of obtaining written permission to use the property at least 3 days prior to anticipated contact with the property owner. Contractor shall limit activities to a distance of no more than 20 from the pipe centerline on private properties. c) Typical allowable working hours are 7 am to 7 pm. MMSD shall apply for a variance from the City or municipality to allow working hours before 7 am and after 7 pm if the Project Engineer determines that it is necessary. MMSD cannot guarantee that a variance will be granted or specify what the allowable working hours will be should a variance be granted. (13) CLEAN-UP Upon acceptance of the installed work and testing, the Contractor shall restore the project area affected by the operations to a condition at least equal to that existing prior to the work. Any grass areas disturbed shall be fine graded, seeded, and mulched. Clean up includes, but is not limited to removing rubbish, debris, dirt, equipment and excess material from the site. The Contractor shall clean adjacent surfaces soiled by and during the course of work. (14) LIQUIDATED DAMAGES Liquidated damages in the amount of $ per calendar day shall be enforced by the District and shall be paid to the District by the Contractor for each day beyond either deadline stated above that the required work remains incomplete. (15) MAINTENANCE RETAINER The sum of five thousand dollars ($5,000.00) will be withheld from the Contractor by the Madison Metropolitan Sewerage District for a period of one year after completion and acceptance of all the Work as a guarantee that the Contractor shall provide all necessary maintenance, re-work, or repair related to rehabilitation work or other work which is determined by the Engineer to be defective. SECTION 204 CURED-IN-PLACE PIPE LINER (1) MATERIALS a) Tube Heat Cure CIPP S-9

10 i) The tube material shall meet the requirements of ASTM F1216. ii) The tube shall consist of one or more layers of absorbent non-woven felt capable of carrying resin and be compatible with the resin system used. The tube shall be capable of withstanding installation pressures and curing temperatures. The tube shall have sufficient strength to bridge missing pipe and stretch to fit irregular pipe sections. iii) The wet out tube shall have a uniform thickness that when compressed at installation pressures will meet or exceed the design thickness. iv) The tube shall be sewn to a size that when installed will tightly fit the internal circumference and length of the original pipe. Allowance should be made for circumferential stretching during inversion. Overlapped layers of felt in longitudinal seams that cause lumps in the final product shall not be utilized. v) The outside layer of the tube (before wet out) shall be coated with an impermeable, flexible membrane that will contain the resin and facilitate monitoring of resin saturation during the resin impregnation (wet out) procedure. vi) The tube shall be homogeneous across the entire wall thickness containing no intermediate or encapsulated elastomeric layers. No material shall be included in the tube that may cause delamination in the cured CIPP. No dry or unsaturated layers shall be evident. vii) The wall color of the interior pipe surface of CIPP after installation shall be a light reflective color so that a clear detailed examination with closed circuit television inspection equipment may be made. viii) Seams in the tube shall be stronger than the non-seamed felt. b) Tube Ultraviolet Light Cure CIPP i) The tube material shall be made of non corrosion material and shall be free from tears, holes, cuts, foreign materials and other surface defects. The fiberglass tube shall be constructed to withstand installation pressures as required by the Manufacturer s recommendations. ii) The interior and exterior foil shall be styrene resistant along with the ability to protect and contain the resin within the liner, with the exterior foil being impermeable to light. iii) The liner should be seamless and spirally wound in its cured state to ensure homogenous physical properties around the circumference of the cured liner. iv) The nominal fiberglass tube wall thickness shall be constructed to the nearest 0.5 mm increment, rounded up from the design thickness for that section of installed CIPP. v) The fiberglass tube shall be manufactured to a size that when installed will tightly fit the internal circumference and the length of the original conduit. The tube shall be able to stretch to fit irregular pipe sections and negotiate bends. c) Resin Heat Cure CIPP i) The resin system shall meet the requirements of ASTM F1216. ii) The resin system shall be a corrosion resistant polyester, vinyl ester, or epoxy and catalyst system that when properly cured within the tube composite meets the requirements of ASTM F1216, the physical properties herein, and those requirements, which are to be utilized in the design of the CIPP for this project. The resin shall produce CIPP, which will comply with the structural and chemical resistance requirements of this specification. d) Resin Ultraviolet Light Cure CIPP- i) The resin system shall produce a cured liner pipe resistant to shrinkage, corrosion, and abrasion and shall have a proven resistance to municipal wastewater. ii) The resin system shall be a chemically resistant isophthalic based polyester thermoset resin and catylst system, or epoxy resin and hardener that are compatible with the installation process. S-10

11 iii) The resin should be able to cure with ultraviolet light. When properly cured the resin/liner system shall meet the structural and chemical resistance requirements of ASTM F e) Structural Requirements Cured-in-Place-Pipe i) The CIPP shall be designed as per ASTM F1216. ii) The CIPP design shall assume no bonding to the original pipe wall. iii) Contractor must have performed long-term testing for flexural creep of the CIPP pipe material installed by his Company. Such testing results are to be used to determine the long-term, time dependent flexural modulus to be utilized in the product design. This is a performance test of the materials (Tube and Resin) and general workmanship of the installation and curing. A percentage of the instantaneous flexural modulus value (as measured by ASTM D-790 testing) will be used in design calculations for external buckling. The percentage, or the long-term creep retention value utilized, will be verified by this testing. Values in excess of 50% will not be applied unless substantiated by qualified third party test data. The materials utilized for the contracted project shall be of a quality equal to or better than the materials used in the long-term test with respect to the initial flexural modulus used in Design. iv) The Enhancement Factor K to be used shall not be greater be than 7. v) The bond between the layers of the cured CIPP shall be strong and uniform. It shall not be possible to separate any two layers with a probe or point of a knife blade so that the layers separate cleanly or the probe or knife blade moves freely between the layers. If separation of the layers occurs during testing of field samples, new samples will be cut from the work. Any reoccurrence may cause rejection of the work. vi) The cured pipe material (CIPP) shall conform to the structural properties, as listed below. MINIMUM PHYSICAL PROPERTIES Cured Composite Cured Composite Property Test Method per ASTM F1216 (400,000 psi Resin) Modulus of Elasticity ASTM D-790 (short term) 250,000 psi 400,000 psi Flexural Stress ASTM D-790 4,500 psi 4,500 psi vii) The required structural CIPP wall thickness shall be based as a minimum, on the following physical properties and in accordance with the Design Equations in Appendix X.I of ASTM F1216. The liner thickness calculations shall assume the following: (1) Minimum ovality of host pipe shall be 3% (2) Enhancement factor (K) shall not be greater than 7.0 (3) Minimum safety factor shall be 2.0 (4) Flexural modulus of elasticity shall be reduced by 50% to account for long term. (5) Existing pipe is a "fully deteriorated pipe". (6) Depths as shown in Section 104 (7) Soil load of 120 lbs./cu.ft. (8) Water table two (2) feet below the ground elevation viii) Any layers of the tube that are not saturated with resin prior to insertion into the existing pipe shall not be included in the structural CIPP wall thickness computation. (2) TESTING REQUIREMENTS a) Chemical Resistance - The CIPP shall meet the chemical resistance requirements of ASTM F1216. CIPP samples for testing shall be of the same tube and resin system as that proposed for S-11

12 actual construction. It is required that CIPP samples with and without plastic coating meet these chemical testing requirements. b) Hydraulic Capacity The Contractor shall provide calculations that demonstrate that the liner pipe shall have at least 100% of full flow capacity of the original pipe before rehabilitation in a full gravity flow condition. Calculated capacities may be derived using a commonly accepted roughness coefficient for the original pipe material. A typical roughness coefficient of the liner pipe shall be as verified by third party test data. c) Field Samples The Contractor shall submit test results from field installations of the same resin system and tube materials as proposed for the actual installation. These test results must verify that the CIPP physical properties specified in Section 204(1)(e) of these Specifications have been achieved in previous field applications. (3) CIPP INSTALLATION The CIPP installation shall be in accordance with ASTM F1216 for Heat Cure CIPP systems. Ultraviolet Light Cured systems shall be installed according to the manufacturer s specifications and applicable ASTM F2019 standards a) Resin Impregnation i) For Heat Cure CIPP systems, the quantity of resin used for tube impregnation shall be sufficient to fill the volume of air voids in the tube with additional allowances of 5% to 10% excess resin for polymerization shrinkage and the loss of resin through cracks and irregularities in the original pipe wall. A vacuum impregnation process shall be used. To insure thorough resin saturation throughout the length of the felt tube, the point of vacuum shall be no further than 25 feet from the point of initial resin introduction. ii) After vacuum in the tube is established, a vacuum point shall be no further than 75 feet from the leading edge of the resin. The leading edge of the resin slug shall be as near to perpendicular as possible. A roller system shall be used to uniformly distribute the resin throughout the tube. If the Installer uses an alternate method of resin impregnation, the method must produce the same results. Any alternate resin impregnation method must be proven. iii) For Ultraviolet Light Cure CIPP systems, the (wet-out) fiberglass tube shall meet ASTM F2019 as applicable, and shall have a uniform thickness and excess resin distribution that when compressed at installation pressures will meet or exceed the design thickness after cure. iv) A certified Wet Out Report shall be completed, signed, and submitted for each liner delivered to the site. The Wet Out Report shall include, but is not limited to, wet-out date, resin identification, resin weight, resin admixtures, fabric tube length, diameter, and thickness. b) Tube Insertion i) The wet out tube shall be positioned in the pipeline using either inversion (ASTM F1216) or a pull-in method (ASTM F1743). Ultraviolet Light Cure CIPP systems must use a pullin method. If pulled into place, a power winch shall be utilized and care shall be exercised not to damage the tube as a result of pull-in friction. The tube shall be pulledin or inverted through an existing manhole or approved access point and fully extend to the next designated manhole or termination point. ii) Temperature gauges shall be placed inside the tube at the invert level of each end to monitor the temperatures during the cure cycle. iii) Curing shall be accomplished by utilizing hot water under hydrostatic pressure or steam cure method in accordance with the manufacturer s recommended cure schedule. c) Tube Insertion- Inversion S-12

13 i) Using Hydrostatic Head- The wet-out tube shall be inserted through an existing manhole or other approved access by means of an inversion process and the application of a hydrostatic head sufficient to fully extend it to the next manhole or termination point. The tube shall be inserted into the vertical inversion standpipe with the impermeable plastic membrane side out. At the lower end of the inversion standpipe, the tube shall be turned inside out and attached to the standpipe so that a leakproof seal is created. The inversion head shall be adjusted to be of sufficient height to cause the impregnated tube to invert from point of inversion to 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. ii) Using Air Pressure- The wet-out tube shall be inserted through an existing manhole or other approved access by means of an inversion process and the 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 and with the impermeable plastic membranes side out, As the tube enters the guide chute, the tube shall be turned inside out. The inversion air pressure shall be adjusted to be of sufficient pressure to cause the impregnated tube to invert from point of inversion to 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 overstress the woven and nonwoven materials. iii) Required Pressures- Before the inversion begins, the tube manufacturer shall provide the minimum pressure required to hold the tube tight against the existing conduit, and the maximum allowable pressure so as not to damage the tube. Once the inversion has started, the pressure shall be maintained between the minimum and maximum pressures until the inversion has been completed. d) Tube Insertion- Pull-in Method i) Perforation of Resin-Impregnated Tube- Prior to pulling the resin-impregnated fabric in place, the outer impermeable plastic coating may optionally be perforated. When the resin-impregnated fabric tube is perforated, this shall allow resin to be forced through the perforations and out against the existing conduit by the force of the hydrostatic head or air pressure against the inner wall of the calibration hose. The perforation shall be done after fabric tube impregnation with a perforating roller device at the point of manufacture or at the jobsite. Perforations shall be made on both sides of the lay-flat fabric tube covering the full circumference with a spacing no less than 1.5 in. (38.1 mm) apart. Perforating slits shall be a minimum of 0.25 in. (6.4 mm) long. ii) Pulling Resin-Impregnated Tube into Position- The wet-out fabric tube shall be pulled into place using a power winch. The saturated fabric tube shall be pulled through an existing manhole or other approved access to fully extend to the next designated manhole or termination point. Care shall be exercised not to damage the tube as a result of friction during pull-in, especially where curvilinear alignments, multilinear alignments, multiple offsets, protruding services, and other friction-producing host pipe conditions are present. Once the fabric tube is in place, it shall be attached to a vertical standpipe so that the calibration hose can invert into the center of the resin-impregnated fabric tube. The vertical standpipe shall be of sufficient height of water head to hold the fabric tube tight to the existing pipe wall, producing dimples at side connections. A device such as a dynamometer or load cell shall be provided on the winch or cable to monitor the pulling force. Measure the overall elongation of the fabric tube after pull-in completion.. The acceptable longitudinal elongation shall not be more than 5% of the overall length measured after the calibration hose has been installed, or exceed the recommended pulling force. e) Lubricant During Installation S-13

14 i) The use of a lubricant during installation is recommended to reduce friction during inversion. This lubricant shall be poured into the field in the standpipe in order to coat the calibration hose, the lubricant shall be applied directly to the calibration hose. ii) The lubricant used shall be a nontoxic, oil-based product that has no detrimental effects on the tube or boiler and pump system, and will not adversely affect the fluid to be transported. f) Curing For Heat Cure CIPP systems, curing shall be accomplished by utilizing circulating heated water or steam under hydrostatic pressure in accordance with ASTM F 1216 and the manufacturer s recommended cure schedule. For Ultraviolet Light Cure CIPP systems, curing shall be accomplished by utilizing air pressure and ultraviolet light in accordance with ASTM F 2019 and the manufacturer s recommended cure schedule. g) Curing- Circulating Heated Water i) After inversion is completed, suitable heat source and water recirculation equipment are required to circulate heated water throughout the pipe. The equipment shall be capable of delivering hot water throughout the section to uniformly raise the water temperature above the temperature required to affect a cure of the resin. Water temperature in the line during the cure period shall be as recommended by the resin manufacturer. ii) The heat source shall be fitted with suitable monitors to gage the temperature of the incoming and outgoing water supply. Another such gage shall be placed between the impregnated tube and the pipe invert at the termination to determine the temperatures during cure. h) Curing- Steam i) After inversion is completed, suitable steam-generating equipment is required to distribute steam throughout the pipe. The equipment shall be capable of delivering steam throughout the section to uniformly raise the temperature within the pipe above the temperature required to affect a cure of the resin. The temperature in the line during the cure period shall be as recommended by the resin manufacturer. ii) The steam-generating equipment shall be fitted with a suitable monitor to gage the temperature of the outgoing steam. The temperature of the resin being cured shall be monitored by placing gages between the impregnated tube and the existing pipe at both ends to determine the temperature during cure. iii) Steam curing systems shall include an elevated steam discharge. The City of Madison Construction Inspector shall monitor and record styrene levels at this point for each liner curing. At direction of the Construction Inspector any steam condensate or styrene residue shall be cleaned and disposed at the Contractor s expense. i) Curing- Ultraviolet Light j) Initial Cure i) After inversion is completed, the fiberglass liner shall be cured with ultraviolet light sources at a constant inner pressure. The ultraviolet light sources shall be assembled according to the Manufacturer s specifications for the liner. The defined parameters for curing speed, inner air pressure, exothermic temperatures, and wattage are to be controlled, measured, and documented during the entire curing process to be submitted to the Engineer with the post CCTV inspection. The inner material should be removed and discarded after curing to provide optimal quality of the final product. S-14

15 k) Required Pressure l) Cool-Down Initial cure will occur during temperature heat-up and is completed when exposed portions of the new pipe appear to be hard and sound and the remote temperature sensor indicates that the temperature is of a magnitude to realize an exotherm or cure in the resin. After initial cure is reached, the temperature shall be raised to post-cure temperatures recommended by the resin manufacturer. The post-cure temperature shall be held for a period as recommended by the resin manufacturer, during which time the recirculation of the water and cycling of the boiler or distribution and control of steam to maintain the temperature continues. The curing of the CIPP must take into account the existing pipe material, the resin system, and ground conditions (temperature, moisture level, and thermal conductivity of soil). The estimated maximum and minimum pressure required to hold the flexible tube tight against the existing conduit during the curing process shall be provided by the manufacturer and shall be increased to include consideration of the external ground water, if present. Once the cure has started and dimpling for laterals is completed, the required pressures shall be maintained until the cure has been completed. The pressure shall be maintained within the estimated maximum and minimum pressure during the curing process. If the steam pressure or hydrostatic head drops below the recommended minimum during the cure, the CIPP shall be inspected for lifts or delaminations and evaluated for its ability to fully meet the applicable requirements of these specifications and ASTM F1216 or ASTM F2019. i) Using Cool Water After Heated Water Cure- The new pipe shall be cooled to a temperature below 100 F (38 C) before relieving the static head in the inversion standpipe. Cool-down may be accomplished by the introduction of cool Water into the inversion standpipe to replace Water being drained ůom a small hole made in the downstream end. Care shall be taken in the release of the static head so that a vacuum will not be developed that could damage the newly installed pipe. ii) Using Cool Water After Steam Cure- The new pipe shall be cooled to a temperature below 113 F (45 C) before relieving the internal pressure within the section. Cool-down may be accomplished by the introduction of cool water into the section to replace the mixture of air and steam being drained from a small hole made in the downstream end. Care shall be taken in the release of the air pressure so that a vacuum will not be developed that could damage the newly installed pipe. (4) SEALING LINER AT MANHOLES a) The Contractor shall reconstruct benches and channels in manholes with grout to match new invert elevations. b) The Contractor shall provide a watertight seal between the host pipe and liner pipe at the connection to the manholes. Seals shall be made with an epoxy or resin mixture compatible with the liner/resin system. Hydraulic cements and quick-set cement products are not acceptable. (5) REINSTATEMENT OF SERVICE CONNECTIONS a) The Contractor shall be responsible for confirming the locations of all service connections prior to installing and curing the CIPP. All service connections shall be reconnected unless otherwise S-15

16 directed by the Engineer. Service connections shall not be out of service for more than 12 hours during the lining process. b) The Contractor shall reinstate all service connections to buildings without excavation, utilizing a remote controlled cutting device, monitored by a video TV camera. The Contractor shall certify he has a minimum of 2 complete working cutters plus spare key components on the site before each inversion. i) Service connections shall be reestablished to a minimum of 95% of the existing flow capacity. ii) Liner shall be sufficiently tight so that there is no annular space between the connection and the liner. c) No additional payment will be made for excavations for the purpose of reopening connections and the Contractor will be responsible for all costs and liability associated with such excavation and restoration work. (6) CHEMICAL GROUTING OF SERVICE CONNECTIONS a) The intent of lateral connection sealing is to test and seal sewer lateral connections using a specialized chemical grout packer. The purpose of this procedure is the elimination of infiltration into sewers that are otherwise structurally sound. b) The Contractor shall proof test each reinstated service connection via an air test or other approved method. Service connections shall be air tested by isolating the area to be tested with the packer and applying positive pressure into the isolated void area. A sensing unit shall be used for continuous monitoring of the void pressure. This sensing unit shall be located within the void area and accurately transmit pressure readout to the control panel. The test procedure shall consist of applying air pressure into each isolated VOID area. To isolate a VOID, the lateral sealing packer shall be positioned straddling the service connection. The operator shall inflate the packer ends to isolate the service connection and insert an inflatable inversion tube. The service connection shall be tested with a gauge pressure of one-half (1/2) p.s.i. per foot of depth of sewer or a minimum of four (4) p.s.i., whichever is larger. The VOID pressure shall be observed during this test for a minimum of 10 seconds. If the VOID pressure drop is greater than1 psi in 10 seconds, the service connection is considered to have failed the air test. If no pressure can be built up, the connection will also have failed the test. Any connection failing the test shall be sealed and retested utilizing the same method and procedures until it does pass the test. The cost of retesting lateral connections shall be considered incidental and included in the cost of sealing sanitary sewer lateral connection. c) Active leaks at reinstated service connections and reinstated connections that do not pass a proof test shall be sealed by chemical grout or other method approved by the Engineer. Seals shall extend from sanitary sewer main into the service connection for a minimum of 18 inches. Grout shall be 3M Scotch Seal #5619 Polyurethane, DeNeef Multigel Polyurethane and Avanti International AV118 Duriflex or equal. (7) INSPECTION & TESTING a) CIPP samples shall be prepared and physical properties tested in accordance with ASTM F1216. The flexural properties must meet or exceed the values listed in Table 1 of the applicable ASTM. i) For each inversion length, one CIPP sample shall be cut from a section of cured CIPP at an intermediate manhole or at the termination point that has been inverted through a like diameter pipe which has been held in place by a suitable heat sink, such as sandbags. S-16

17 ii) The sample should be large enough to provide five specimens for flexural testing and also for tensile testing. The full CIPP sample wall thickness shall be tested, whenever possible. If the sample is irregular, distorted, or of such thickness that proper testing is inhibited, then the wall thickness shall be machined away from the inside pipe face of the sample only. Thus, the test specimen shall be cut from the outside pipe face of the CIPP sample. For specimens greater than 1/2-inch (12.70 mm) depth, the width-to-depth ratio of the specimen shall be increased to a minimum of 1:1 and shall not exceed 4:1. Test specimens shall be oriented on the testing machine with the interior surface of the CIPP in tension. The test procedures below should be followed after the sample is cured and removed. iii) Tensile Strength (1) Test in accordance with ASTM D638. (2) Specimens tested shall be actual thickness of fabricated liner. (3) Tensile strength shall be average of 5 specimens tested. iv) Flexural Strength and Modulus of Elasticity (1) Test in accordance with ASTM D790. (2) Specimens tested shall be actual thickness of fabricated liner. (3) Make test with smooth (inner) face in compression using 5 specimens. b) Visual inspection of the CIPP shall be in accordance with ASTM F1216. i) Televise interior of pipe after completion of Work and provide tape to Engineer. ii) Use pan and tilt color 3-lux camera to view the sewer service connection reinstatement. S-17