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F. Watertight type manhole frames with 32-inch diameter covers (bolted and gasketed) shall be
4 bolt, 630 pounds minimum by E.L. LeBaron Foundary Co. No. LCB328; Quality Water
Products, Style C47WT; Neenah Foundary Co., R-17550-H or approved equal.

G. Catch basin frames with 2-1inch square openings and 23-7/8-inch square grates shall be 8-
inches in height and 460 pounds minimum. They shall be Neenah Foundry Co. No. 3405;
Quality Water Products No. 45; E.L. LeBaron Type F; or approved equal.

H. — Catch basin frames with bar grate openings and 23-7/8-inch square grates shall be 8-inches in
height and 460 pounds minimum. Bar grates shall not be used in areas where bicycle
traffic could be present. They shall be Neenah Foundry Co. No. R-3589; Quality Water
Products No. 45; E.L. LeBaron LK121; or approved equal.

I. Catch basin frames with cascade grate openings and 23-7/8-inch square grates shall be 8-
inches in height and 430 pounds minimum. They shall be Neenah No. R-3589; Quality
Water Products Mass Standard; E.L. LeBaron No. LK121A; or approved equal.

J. Catch basin frames set against curbing shall have three flanges only. 2.04

SEWER MANHOLE ACCESSORIES:

A. Gasket materials shall be top grade (100% solids, vulcanized) butyl rubber and shall meet or
exceed AASHTO M-198.

B. Couplings at the manhole-pipe interface shall be made with a rubber seal system (with or
without stainless steel straps) meeting the requirements of ASTM C923 and recommended
for this type of connection.

C. — Stubs installed as specified and indicated on the drawings shall be short pieces of the same

class pipe as that entering the manhole and shall have either stoppers or end caps as shown on
the drawings. Stoppers or end caps shall be especially designed for that application.

PART 3 - EXECUTION
3.01 INSTALLATION:

A. PRECAST SECTIONS:

1. Precast bases shall be supported on a compacted level foundation of crushed stone, as
specified in Section 02300 EARTHWORK, at least 6-inches thick, but shall vary to
the depth necessary to reach sound undisturbed earth.

2. Precast reinforced concrete sections shall be set vertical and with sections in true
alignment.
3. Butyl rubber joint sealant shall be installed between each concrete section. Catch

basin sections do not require joint sealant if so indicated on the drawings.

0263 1-5

All holes in sections used for handling the sections shall be thoroughly plugged with
mortar. Mortar shall be one part cement to 1-1/2 parts sand, mixed slightly damp to
the touch (just short of "balling"), hammered into the holes until it is dense and an
excess of paste appears on the surface, and then finished smooth and flush with the
adjoining surfaces.

BRICK WORK:

1. Bricks shall be moistened by suitable means, as directed, until they are neither so dry as to

absorb water from the mortar nor so wet as to be slippery when laid.

Each brick shall be laid as a header in a full bed and joint of mortar without requiring
subsequent grouting, flushing or filling, and shall be thoroughly bonded as directed.

The brick inverts shall conform accurately to the size of the adjoining pipes. Side
inverts shall be curved and main inverts (where direction changes) shall be laid out in
smooth curves of the longest possible radius which is tangent to the centerlines of
adjoining pipe.

CASTINGS:

1.

Cast iron frames, grates and covers shall be as specified. The frames and covers
shall be set by the Contractor to conform accurately to the grade of the finished
pavement, existing ground surface, or as indicated on the drawings. Frames shall be
adjusted to meet the street surface.

Cast iron manhole frames and covers not located in paved areas shall be set 6-inches
above finished grade, at a height as directed by the Engineer, or as indicated on the
drawings. The top of the cone shall be built up with a minimum of 1 course and a
maximum of 5 courses of brick and mortar used as headers for adjustment to final
grade.

Frames shall be set concentric with the top of the concrete section and in a full bed of
mortar so that the space between the top of the concrete section or brick headers and
the bottom flange of the frame shall be completely filled and made watertight. A
thick ring of mortar extending to the outer edge of the concrete shall be placed all
around the bottom flange. The mortar shall be smoothly finished to be flush with the top
of the flange and have a slight slope to shed water away from the frame.

Covers and/or grates shall be left in place in the frames, for safety reasons, except
while work is being performed.

ACCESSORIES:

1.

2.

Accessories shall be installed in accordance with manufacturer's instructions.

Stubs shall be set accurately to the dimensions indicated on the drawings. Stubs
shall be sealed with suitable watertight plugs.

0263 1-6

3.02 LEAKAGE TESTS:

A. Leakage tests shall be made by the Contractor and observed by the Engineer on each
manhole. The test shall be by vacuum or by water exfiltration as described below:

B. VACUUM TEST:

1. The vacuum test shall be conducted in accordance with ASTM C1244. Test results will
be judged by the length of time it takes for the applied vacuum to drop from 10 inches
of mercury to 9 inches. If the time is less than that listed in Table 1 of ASTM C1244,
the manhole will have failed the test. Test times from Table 1 are excerpted below.

TABLE 1 Minimum Test Times for Various Manhole Diameters

Diameter (Inches)
Depth (Feet) 48 60 72
Times ( oeconds)
0-1 30 39 49
016 40 52 67
16-20 50 65 81
50.04 59 78 97
76-30 74 98 121

2. If the manhole fails the initial test, the Contractor shall locate the leaks and make
proper repairs. Leaks may be filled with a wet slurry of accepted quick setting
material. If the manhole should again fail the vacuum test, additional repairs shall be
made, and the manhole water tested as specified below.

C. WATER EXFILTRATION TEST:

1. After the manhole has been assembled in place, all lifting holes shall be filled and
pointed with an approved non-shrinking mortar. All pipes and other openings into the
manhole shall be suitably plugged and the plugs braced to prevent blow out. The test
shall be made prior to placing the shelf and invert. If the groundwater table has been
allowed to rise above the bottom of the manhole, it shall be lowered for the duration
of the test.

2. | The manhole shall be filled with water to the top of the cone section. If the
excavation has not been backfilled and observation indicates no visible leakage, that 1s,
no water visibly moving down the surface of the manhole, the manhole may be
considered to be satisfactorily water-tight. If the test, as described above, 1s
unsatisfactory as determined by the Engineer or 1f the manhole excavation has been
backfilled, the test shall be continued. A period of time may be permitted if the
Contractor so wishes, to allow for absorption by the manhole. At the end of this
period, the manhole shall be refilled to the top of the cone, if necessary, and a
measuring time of at least 8 hours begun. At the end of the test period, the manhole
shall be refilled to the top of the cone, measuring the volume of water added. This
amount shall be extrapolated to a 24-hour loss rate and the leakage determined on the

0263 1-7

3.03

basis of depth. The leakage for each manhole shall not exceed one gallon per
vertical foot for a 24-hour period. If the manhole fails this requirement, but the
leakage does not exceed 3 gallons per vertical foot per day, repairs by approved
methods may be made as directed by the Engineer to bring the leakage within the
allowable rate of one gallon per foot per day. Leakage due to a defective section or
joint or exceeding the 3 gallon per vertical foot per day, shall be cause for rejection of
the manhole. It shall be the Contractor's responsibility to uncover the rejected
manhole as necessary and to disassemble, reconstruct or replace it as directed by the
Engineer. The manhole shall then be retested and, if satisfactory, interior joints shall be
filled and pointed.

No adjustment in the leakage allowance will be made for unknown causes such as
leaking plugs, absorption, etc. It shall be assumed that all loss of water during the
test is a result of leaks through joints or through the concrete. Furthermore, the
Contractor shall take any steps necessary to assure the Engineer that the water table 1s
below the bottom of the manhole throughout the test.

If the groundwater table 1s above the highest joint in the manhole, and there is no
leakage into the manhole, as determined by the Engineer, such a test can serve to
evaluate water-tightness of the manhole. However, if the Engineer is not satisfied
with the results, the Contractor shall lower the water table and carry out the test as
described hereinbefore.

CLEANING:

All new manholes shall be thoroughly cleaned of all silt, debris and foreign matter of any
kind, prior to final inspection.

END OF SECTION

02631-8

SECTION 02650

CURED-IN-PLACE PIPE (CIPP) LINING OF EXISTING SEWERS

PART 1 GENERAL

1.01 DESCRIPTION

A.

SCOPE

The work consists of furnishing all labor, equipment, materials, and incidentals
required to rehabilitate existing sewer mains by the installation of cured-in-place
pipe (CIPP) into the existing main. Work will include bypass pumping, sewer
cleaning, initial closed circuit television (CCTV) inspection of sewers to be lined,
installation of liner, reconnection of service connections, final closed circuit
television (CCTV) inspection, and all other related work. All such work shall
comply with these specifications and the specific product manufacturer’s
recommendations. Any conflict between the product manufacturer’s
recommendations and any portion of the contract documents shall be resolved
with the Owner prior to proceeding with the work.

SAFETY

This standard does not address safety problems associated with the use of this
product. It is the responsibility of the user of this standard to establish appropriate
safety and health practices and determine the applicability of regulatory limitations
prior to use.

1.02 REFERENCES

A.

ASTM STANDARDS
The following references are part of this Specification. The latest edition of the
following references shall be used:

ASTM D 543: Standard Test Methods for Resistance of Plastics to
Chemical Reagents.

ASTM D 638: Standards Test Methods for Tensile Properties of
Plastics.
ASTM D 790: Standard Test Methods for Flexural Properties of

Unreinforced and Reinforced Plastics and Electrical
Insulating Materials.

ASTM D2990: Standard Test Methods for Tensile, Compressive,
and Flexural Creep and Creep-Rupture of Plastics.

ASTM F 1216: Standard Practice for Rehabilitation of Existing
Pipelines and Conduits by the Inversion and Curing
of a Resin-Impregnated Tube.

02650-1

ASTM F 1743: Rehabilitation of Existing Pipelines and Conduits

by Pulled-in-Place Installation of Cured-in-Place
Thermosetting Resin Pipe (CIPP)

* (Note: The Contractor may substitute an alternative method other than by
inversion to install the liner, as approved by the Engineer.

1.03 QUALITY ASSURANCE

A. REQUIREMENTS

1.

Products used in the work of this section shall be produced by manufacturers
regularly engaged in the manufacture of cured-in-place liners for municipal
wastewater systems and with a history of successful production acceptable to
the owner.

The installing Contractor shall be licensed by the cured-in-place lining system
manufacturer and shall have successful experience in the installation of cured-
in-place lining systems in municipal wastewater systems. The Contractor shall
also be familiar with the specified requirements and the methods needed for
proper performance of the work of this section.

. When requested by the owner, the Contractor shall submit evidence acceptable

to the owner, such as a certified copy of a license or agreement, that it has the
authority to use and/or install the liner product.

The finished liner shall be continuous over the entire length of the liner
insertion run between the manholes and shall be free from visual defects such
as foreign inclusions, dry spots, pinholes, and delamination.

Wrinkles in the finished liner pipe which cause a backwater of one inch or
more or reduce the hydraulic capacity of the pipe are unacceptable and shall be
removed or repaired by the Contractor. If a void between the wrinkle and the
pipe develops, the Contractor shall repair or replace that section of the pipe.
Methods of repair shall be proposed by the Contractor and submitted to the
owner for review.

Following sewer cleaning and prior to installation of liner and finish work at
the manholes, the sewer shall be televised and recorded on videotape or in
digital format acceptable to the Engineer such as CD or DVD, and shall be
provided to the Engineer. The Contractor shall also televise the sewer after
completion of all liner insertion and finish work at the manholes. All Closed-
Circuit Television (CCTV) work is to be completed per a national standard for
sewer inspections.

02650-2

7. The Contractor installing the Sectional Lining system shall have completed at
least three (3) projects, in the United States, within the past three (3) years and
projects that included CIPP installation lengths of at least 300 continuous
linear feet, on-site wet-out or resin impregnation of the liner tube, and design
of a similarly sized Sectional Liner wall thickness based on a fully deteriorated
condition.

8. Supervisory personnel shall have a minimum of three (2) years experience and
shall have completed at least two (2) projects of similar size and complexity as
this project with the United States within the past three (3) years. Attach
r[Jsum[]s of each person named. R[Jsum[] information shall include, at a
minimum, educational background, the number of years in a supervisory
capacity and a list of completed projects within the past two (2) years,
including project description, complexity and contract total amounts.

1.04 SUBMITTALS

The Contractor shall submit the following information:

A.

MATERIALS

Contractor shall provide submittals on all lining materials and resins, and shall
furnish the manufacturers’ certifications that all of the liner materials are in
compliance with the specifications, codes, and standards referenced herein. The
submittals shall include installation instructions and details of all component
materials and construction methods. The Contractor shall also provide the liner
tube manufacturer’s certifications, field measurements, and pipe sizing
calculations which demonstrate that the liner tube has been properly sized to avoid
the creation of wrinkles or folds. The Contractor shall furnish Material Safety
Data Sheets for all appropriate materials to be used in the project.

INSTALLATION

The Contractor shall submit the method of liner insertion, liner size, thickness
calculations, and assumptions used as the basis for calculations for review by the
Engineer prior to the start of work. The liner shall provide complete structural
support without considering any structural support from the existing pipe except
during construction.

1.04 WARRANTY

A.

WARRANTY

The Contractor shall provide the Owner with a warranty to be in force and effect
for a period of one (1) year from the date of final acceptance of the project by the
Owner. The warranty shall cause the Contractor to repair or replace the liner
should failure or damage result from faulty materials or installation. At the end of
the warranty period, the Owner may perform a television inspection to confirm the
condition of the liner.

02650-3

PART 2 MATERIALS

2.01 GENERAL

A. CERTIFICATE OF COMPLIANCE
A Certificate of Compliance with these Specifications shall be provided by the
manufacturer for all materials furnished under these specifications.

2.02 MATERIALS

A. LINER TUBE

1.

The liner tube shall consist of one or more layers of flexible needled felt or an
equivalent non-woven and/or woven material capable of carrying resin,
withstanding installation pressures and curing temperatures, and compatible
with the resin system used. The liner tube shall be fabricated to a size that will
fit the internal circumference of the existing sewer main. Allowance shall be
made for stretching due to insertion of liner and deterioration of existing pipe
walls.

The minimum liner tube length shall be that deemed necessary by the
Contractor to effectively and continuously span the distance from the inlet to
the outlet of the respective manholes, unless otherwise specified. The
Contractor shall verify the lengths in the field before impregnation and
installation of the tube. Individual insertion runs may be made over one or
more manhole sections as determined in the field by the Contractor and
approved by the Engineer.

Prior to insertion, the liner tube shall be free of all visible tears, holes, cuts,
foreign materials, and other defects.

B. RESIN

Unless otherwise specified, the Contractor shall furnish a general purpose,
unsaturated, thermosetting, polyester resin, able to cure in the presence or
absence of water, and a catalyst system compatible with the liner material that
provides the cured physical and chemical resistance strengths specified. The
initiation temperature for cure shall be as recommended by the resin
manufacturer and approved by the Engineer. Upon request, the Contractor
shall furnish satisfactory written certification that the materials comply with
the manufacturer’s standards and the reference specifications.

General corrosion requirements: The liner shall be fabricated from materials
which, when cured, will be chemically resistant to withstand exposure to
normal sewage effluent.

Resin shall not be affected by ultraviolet light and shall form no excessive
bubbling or wrinkling during lining. Resins shall be tinted for visibility and
provide indication of adequate liner wet-out. Material safety data sheets

02650-4

2.03

(MSDS) for the resin, catalyst, cleaners and repair agents should be submitted
to the Engineer for review.

DESIGN AND PHYSICAL PROPERTIES

A.

THICKNESS DESIGN

The liner thickness design shall be based on fully deteriorated conditions, a pipe
ovality of 2%, an allowable deflection of 5%, and the resin’s physical properties
shown in Section 2.03 (D). If the Contractor uses resins having different physical
properties, the Contractor shall submit with the bid, detailed calculations of the
proposed liner thickness for review by the Engineer.

LOADING

The liner shall be designed to withstand all internal and external loads taking into
account internal pressure and external soil pressures, groundwater, paving and full
traffic (H-20 or E-80 loads as applicable), all with safety factor of 2.

STANDARDS
The CIPP system shall conform to and comply with the minimum criteria listed
below:

Characteristic Test Method Polyester Resins
Flexural Strength | ASTM D 790 4,500 psi
Flexural Modulus | ASTM D 790 250,000 psi
(Initial) ASTM D 2990

Flexural Modulus | ASTM D 2990 125,000 psi
(Long Term)*

*Long term is defined as 50 years.

CALCULATIONS
All calculations shall be signed and sealed by a Registered Civil Engineer and be
submitted to the Owner if requested by the Owner.

INSIDE DIAMETER
The net inside diameter of the reconstructed lined sewer shall be as large and
smooth as possible.

WET-OUT

The tube shall be vacuum impregnated with a resin and catalyst system and all
materials and methods utilized shall be in accordance with the requirements of the
particular system utilized.

02650-5

G. MINIMUM THICKNESS
Minimum Liner Thickness unless otherwise specified shall be as follows:

Nominal Pipe Diameter Minimum Thickness

8-inch 45mm
10-inch 6.0 mm
12-inch 6.0 mm
15-inch 7.5mm
> 15-inch <50 SDR

2.04 CHEMICAL RESISTANCE

A. CHEMICAL RESISTANCE
Chemical resistance shall be in accordance with the requirements of Section 8 of
ASTM F 1216, Section X2, Chemical Resistance Tests for polyester resins and
completed in accordance with Test Method D 543. Exposure should be for a
minimum of one month at 73.4 degrees F when subjected to the following
solutions:

Chemical Solution Concentration, %
Tap Water (ph 6-9) 100

Nitric Acid 5

Phosphorus Acid 10

Sulphuric Acid 10

Gasoline 100

Vegetable Oil 100

Detergent 0.1

Soap 0.1

The Contractor shall be responsible for all costs associated with the chemical
resistance tests. Proof of meeting these requirements shall be provided to the
Engineer for approval at least 7 days prior to the commencement of work.

PART 3 INSTALLATIONS
3.01 PREPARATION

A. CLEANING AND INSPECTION
Debris shall be removed from the pipeline with high velocity jet cleaners. The
pipeline shall be inspected with CCTV equipment to assure that the pipe is in a
condition that it can be lined. Obstructions shall be removed and services marked
for reinstatement prior to lining.

02650-6