11-Section 02767 - Monolithic Lining System 031826.pdf

ITB No.: 26-403/DL 02767 - 1 Rehab of Manholes, Sanitary Stations & Wet Wells - Phased Projects.

SECTION 02767

MONOLITHIC LINING SYSTEM

PART 1 – GENERAL

1.01 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required, prepare existing structures for new lining including removal of existing lining and install and test manhole monolithic lining system (MMLS) and appurtenances complete as specified herein. The monolithic lining shall be used to rehabilitate the interior of the designated existing leachate manholes, pump station, and sanitary pump stations. The system shall be suitable for completely sealing out all infiltration in existing manholes/wet wells, preventing corrosion, and restoring structural integrity.

B. The CONTRACTOR shall accurately field measure and size each individual manhole/wet well. The CONTRACTOR is reminded that each existing manholes/wet wells/pump stations designated to receive a monolithic lining may have a different configuration and varying field dimensions. All field measurements shall conform to the requirements of the monolithic lining

MANUFACTURER.

1.02 RELATED WORK (NOT USED)

1.03 SUBMITTALS

A. Submit to the OWNER, as provided in Section 01300, shop drawings and schedules of all monolithic lining Systems (MMLS) and appurtenances. Submit design data and specification data sheets listing all parameters used in the Monolithic lining system design and thickness calculations based on applicable provisions of ASTM C722 and submit P.E. Certification Form for all design data.

B. Submit to the OWNER, within ten (10) days of the Effective Date of the Agreement, a list of Warren Environmental materials to be furnished.

C. Submit a step-by-step description of the methods, practices, intervals, etc. to be used in the application and curing of the monolithic lining system to meet the requirements of this specification section.

D. Test Reports

1. Prior to each shipment of materials, submit certified test reports that the materials for this Contract were

ITB No.: 26-403/DL 02767 - 2 manufactured and tested in accordance with the ASTM Standards specified herein.

1.04 REFERENCE STANDARDS

A. American Society for Testing and Materials (ASTM)

1. ASTM C722 Standard Specification for Chemical-Resistant Resin

Monolithic Surfacings.

2. ASTM C882 Test Method for Bond Strength of Epoxy-Resin Systems

Used with Concrete

3. ASTM C884 Test Method for Thermal Compatibility Between

Concrete and an Epoxy-Resin Overlay

4. ASTM D790 Test Methods for Flexural Properties of

Unreinforced and Reinforced Plastics.

5. ASTM D870 Practice for Testing Water Resistance of Coatings

Using Water Immersion

6. ASTM D1763 Standard Specifications for Epoxy Resins

7. ASTM D2247 Practice for Testing Water Resistance of Coatings in 100% Relative Humidity

8. ASTM D4541 Standard Test Method for Pull-Off Strength of

Coatings using Portable Adhesion Testers.

B. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.

1.05 QUALIFICATIONS

A. The CONTRACTOR performing the work shall be fully qualified, experienced and authorized Warren Environmental products applicator, and equipped to complete this work expeditiously and in a satisfactory manner. The CONTRACTOR shall submit the following information to the OWNER for review and approval before any work is performed.

1. The number of years of experience in performing this type of specialized work with a minimum of 5 years’ experience.

2. The CONTRACTOR shall be an approved Warren Environmental products installer as certified and licensed by the MANUFACTURER. CONTRACTOR shall submit documentation of certification.

3. A list of clients that the CONTRACTOR has performed this type of work.

a. The list shall contain names and telephone numbers of persons who can be called to verify previous satisfactory performance.

b. Installation dates and a description of the actual work performed.

c. The MANUFACTURER shall provide an installation list of his product used for similar manhole/wet well rehabilitation projects. The list shall provide the same information as required in paragraphs 3.a. and 3.b. above.

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B. The CONTRACTOR shall also be capable of providing crews as needed to complete this work without undue delay and shall begin work within seven (7) days from authorized notice to proceed.

C. The installer shall be Warren Environmental’s approved installer trained and certified to install the product. Installation shall be performed under the constant direction of a single field installation supervisor who shall remain on site and be in responsible charge. The field installation supervisor shall have experience with rehabilitation of at least 50 manholes/wet wells.

D. The OWNER reserves the right to approve or disapprove the

CONTRACTOR, based on the submitted qualifications.

1.06 GUARANTEE

A. All monolithic lining placed shall be fully guaranteed by the CONTRACTOR and MANUFACTURER for a period of five (5) years from the date of acceptance. During this period, all defects discovered in the monolithic lining, as determined by the OWNER, shall be repaired or replaced in a satisfactory manner at no cost to the OWNER. Such repair or replacement shall include the cost of removal and reinstallation.

B. The CONTRACTOR shall provide to the OWNER a written form of guarantee from the MANUFACTURER and himself. The guarantee shall state that the design, materials and workmanship shall be free from defects for a period of five (5) years from the date of substantial completion. The written form shall be acceptable to the OWNER and shall be written for the benefit of the OWNER. The guarantee shall contain no exclusions or limitations and shall be submitted as a condition of payment of the work.

C. The CONTRACTOR is responsible for stopping all leaks prior to the installation of the monolithic lining system.

1.07 QUALITY ASSURANCE

A. All monolithic lining shall be from Warren Environmental. The supplier shall be responsible for the provisions for all test requirements specified in ASTM Standards as described herein and as applicable for monolithic lining. In addition, all manhole monolithic lining materials (MMLM) to be installed under this Contract shall be inspected at the site for compliance with these specifications by the Contractor and witnessed by OWNER.

The CONTRACTOR shall require the MANUFACTURER's cooperation in these inspections.

B. Inspections of the MMLM may also be made by the OWNER or other representatives of the OWNER after completion. The MMLM shall be subject to rejection at any time on account of failure to

ITB No.: 26-403/DL 02767 - 4 meet any of the Specification requirements. MMLM rejected after completion shall be marked for identification and shall be repaired at once.

1.08 DELIVERY, STORAGE AND HANDLING

A. Care shall be taken in shipping, handling and placing to avoid damaging the MMLM. Extra care will be necessary during cold weather construction. Any MMLM damaged in shipment shall be replaced as directed by the OWNER.

B. Any MMLM lining showing deterioration, or which has been exposed to any other adverse storage condition that may have caused damage, even though no such damage can be seen, shall be marked as rejected and removed at once from the work.

C. While stored, MMLM lining shall be adequately packaged and protected. MMLM shall be stored in a manner as recommended by the MANUFACTURER.

PART 2 PRODUCTS

2.01 MANHOLE MONOLITHIC LINING SYSTEM (MMLS)

A. The manhole monolithic lining system (MMLS) shall be a resin-filled system suitable for use as a trowel-, spray- or spin-applied monolithic lining in sewer and leachate manholes/wet wells. The resin shall be as in Section 2.01 D. The system shall be resistant to corrosion and shall effectively bond to the substrate surfaces of the existing manholes/wet wells. The MMLS shall conform to ASTM C722. The MMLS materials shall be suitable for all the specified design conditions.

1. The MMLS shall provide a minimum service life of 50 years.

2. The cured MMLS shall be continuously bonded to all the brick, mortar, concrete, chemical sealant, grout, pipe and other surfaces inside the manhole/wet well. Provide bond strength data on cured MMLS based on ASTM C882 test method.

3. The cured MMLS thickness shall be as recommended by the

MANUFACTURER.

4. Chemical sealants or grouts used to seal active manhole leaks, to patch cracks, to fill voids and to otherwise prepare the manhole surfaces shall be compatible with the MMLS. If desired, the CONTRACTOR may apply an initial fiber reinforced corrosion resistant cementitious or epoxy monolithic liner prior to installing the epoxy system. The cementitious system shall be designed for application in sewer manholes and shall be fully compatible with the epoxy system. Contractor shall consult with MMLS manufacturer for compatible cementitious materials.

B. When cured, the MMLS shall form a continuous, tight-fitting, hard, impermeable lining, which is suitable for leachate and

ITB No.: 26-403/DL 02767 - 5 sewer system service and chemically resistant to any chemicals or vapors normally found in leachate and domestic sewage.

C. The MMLS shall bond to the manhole/wet well being rehabilitated after being placed and cured. The MMLS shall cover the complete interior of the existing manhole/wet well including the benches (shelves) and inverts (channels or troughs). The MMLS shall provide a continuous watertight seal or barrier.

1. The MMLS shall effectively seal the interior surfaces of the manhole/wet well and prevent any penetration or leakage of groundwater infiltration.

2. Provide water resistance data on MMLS based on ASTM standards D870 and D2247 test methods.

3. The MMLS shall be compatible with the thermal condition of the existing manhole/wet well surfaces. Surface temperatures will range from 40 degrees F to 100 degrees F. Provide test data on MMLS thermal compatibility based on ASTM C884.

4. The MMLS shall be separated from the manhole/wet well frame by a suitable joint. The joint shall be sealed in accordance with lining MANUFACTURER’s requirements.

D. The MMLS utilized on the sanitary pump stations and manholes shall be as manufactured by Warren Environmental.

PART 3 EXECUTION

3.01 INSTALLATION

A. The CONTRACTOR shall clean each sewer manhole to be surfaced and shall dispose of any resulting material.

1. Use a high-power jet wash at a minimum of 4,000-6,000 psi water pressure. Remove all dust, laitance, biological growths, grease, oil, paint or any other surface contaminants or coatings.

2. Remove existing coating or PVC liner.

3. Coatings that cannot be removed shall be sanded with coarse sandpaper to rough the surface sufficient to obtain and insure adequate bonding of the MMLS.

B. The CONTRACTOR shall conduct a visual inspection of each manhole/wet well after it is cleaned. CONTRACTOR shall notify the OWNER of any unforeseen conditions immediately upon observation. All active, hydrostatic infiltration leaks shall be plugged or sealed with grout. Remove all loose mortar and rubble of existing benches and inverts. Remove any protruding rubber gaskets between wall seams. Prepare manhole to receive MMLS as necessary by reshaping and repairing benches, inverts, and wall where required. Protect all pipe connections. All interior surfaces shall be prepared for MMLS as recommended by the MANUFACTURER.

1. All cracks and other voids must be repaired and filled with recommended non-shrinking cements, sealants or grouts.

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2. All surfaces shall be clean and structurally sound.

3. All surfaces shall be suitably prepared as required by the

MANUFACTURER for the required bonding of the MMLS.

C. Refer to Section 01014 for coordination of system shutdown with the OWNER.

D. The CONTRACTOR shall furnish and place the MMLS in the manhole/wet well. The installation of the MMLS shall be in complete accordance with the applicable provisions of ASTM C722 and the MANUFACTURER’s specifications, and a certified inspector/installer shall be present during the actual installation.

1. Prior to placing the MMLS the certified inspector/installer must approve the surface preparation work and installation conditions including temperatures.

2. All surfaces shall be sufficiently dry and even.

3. All bottom and horizontal surfaces including the benches and channels shall have the MMLS applied to the required thickness by hand trowelling or spray-on methods.

4. All side vertical surfaces shall have the MMLS applied to the required thickness by spincoat mechanical or spray-on method.

5. Temperature limitations must be handled as appropriate and as approved by the MANUFACTURER.

E. All cutting and/or sealing of MMLS at manhole/wet well pipe, cured-in-place liner, rungs and top connections shall provide watertight seals.

F. The CONTRACTOR shall reopen all of the existing active pipe connections in each manhole/wet well following lining.

G. The existing frame and covers, pipe connections and inverts shall be restored to an acceptable condition as approved by the

OWNER.

3.02 FIELD TESTING AND ACCEPTANCE

A. Field acceptance of MMLS shall be based on the OWNER’s/Authority's evaluation of the proper monolithic lining of the manhole/wet well. Field acceptance shall also be based on the ONWER's/Authority’s evaluation of the appropriate installation and curing test data along with review of the manhole inspections.

B. The MMLS shall provide a continuous monolithic lining with uniform thickness throughout the manhole/wet well interior. If the thickness of the MMLS is not uniform or is less than specified, it shall be repaired or replaced at no additional cost to the OWNER.

1. The OWNER will measure the MMLS cured thickness by physically cutting through the lining (by drilling or coring) and making

ITB No.: 26-403/DL 02767 - 7 a direct measurement. There will be up to three thickness measurement locations in each MMLS manhole. A suitable non-destructive type of thickness measurement may also be used.

2. All the MMLS thickness measurement locations shall be repaired by the CONTRACTOR in accordance with the MANUFACTURER's recommendations. These repairs shall be included in the five-year MMLS guarantee.

3. The CONTRACTOR shall also perform in-place testing in each manhole/wet well to verify the bonding of the MMLS to the existing manhole substrate. Bond strength tests shall be in accordance with ASTM D4541 and the test area shall be isolated from the remaining portion of the manhole by coring through the liner into the substrate. Two tests shall be performed in each manhole at locations directed by the OWNER. Testing shall consist of a calibrated pull test. All equipment shall be provided by the CONTRACTOR. Samples must meet a minimum pressure resistance of 400 psi.

C. Groundwater infiltration of the MMLS lining shall be zero.

D. All pipe connections shall be open and clear.

E. There shall be no cracks, voids, pinholes, uncured spots, dry spots, lifts, delaminations or other type defects in the MMLS.

F. Vacuum testing shall be performed on all lined manholes/wet wells in accordance with the following:

1. The test shall be made using an inflatable compression band, vacuum pump, and appurtenances specifically designed for testing manholes. Test procedures shall be in accordance with the equipment MANUFACTURER's recommendations. CONTRACTOR shall be fully familiar with the vacuum testing equipment and shall provide a minimum of four (4) hours of instruction by a factory-authorized representative at the outset of the project.

2. Each manhole/wet well shall be tested immediately after installation of MMSS and after all active pipe connections have been reopened.

3. All pipes entering the manhole/wet well shall be plugged and braced to prevent the plug from being drawn into the manhole/wet well.

4. After the test equipment is in place the test shall be run at the following rate and test times:

a. For 4.0 ft or 5.0 ft diameter manholes.

(1) Initial pressure test - 10-in Hg.

(2) Test time - 1-in Hg drop to 9-in Hg in 1 minute minimum allowable, for 0-10 ft. deep manholes; 1 minute 15 seconds minimum allowable for 10-15 ft deep manholes; 1 minute 30 seconds minimum allowable for 15-25 ft deep manholes.

5. If the pressure drop exceeds 1-in Hg in the specified time the manhole shall be repaired in accordance with approved procedures and retested.

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6. If a manhole fails to meet a 1-in Hg drop in the specified time after repairs, the unit shall be water exfiltration tested and repaired as necessary.

G. Holiday Detection Test: A high voltage holiday detection system may be used to determine if any holidays (pinholes, voids, etc.)

exist in the lining. Normally the sensitivity control of the holiday tester is set to accommodate the thickness of the applied lining (100 - 125 volts for each 1 mil thickness). Follow the guidelines of the holiday MANUFACTURER for correct control settings. One such source is the Tinker & Rasor Holiday Tester Model APW. Should a holiday be detected, it shall be marked, and the lining installation CONTRACTOR will repair the void according to the correct procedure determined by the system

MANUFACTURER.

H. If any defective MMLS is discovered after it has been installed, it shall be repaired or replaced in a satisfactory manner within 72 hours and at no additional cost to the OWNER. Prior to repair or replacement of defective work, representatives of the MMSS MANUFACTURER and installer shall visit the project site to observe the defective work, identify the reason/cause of the defect, and to propose corrective action. All repair and replacement shall be approved by the OWNER prior to proceeding with the corrective action. All completed work shall conform to the field testing and acceptance procedures included in this Section. This requirement shall apply for the entire five-year guarantee period.

END OF SECTION