C05 Attachment 12 Specs Polymer Concrete Structures.pdf

STANDARD SPECIFICATION POLYMER CONCRETE STRUCTURES

POLYMER CONCRETE STRUCTURES

PART 1 GENERAL

1.01 SCOPE

This specification covers polymer concrete structures (manholes, lift stations, non-cylindrical structures) intended for use in sanitary sewers, storm sewers, water lines and other applications where corrosion resistance is required.

1.02 REFERENCES

ASTM C 478 (most current) Standard Specification for Precast Reinforced Concrete Manhole Sections.

ASTM C 579 (most current) Standard Test Methods for Compressive Strength of Chemical-Resistant Mortars, Grouts, Monolithic, Surfacing, and Polymer Concretes

ASTM C 443 (most current) Standard Specification for Joints for Concrete Pipe and Manholes Using Rubber Gaskets

ASTM C 580 (most current) Standard Test Method for Flexural Strength and Modulus of Elasticity of Chemical-Resistant Mortars, Grouts, Monolithic Surfacing's, and Polymer Concretes

ASTM C 857 (most current) Standard Practice for Minimum Structural Design Loading for Underground Utility Structures.

ACI 350-06 Code Requirements for Environmental Engineering Concrete Structures & Commentary

ACI 440.1R-15 Guide for the Design and Construction of Structural Concrete Reinforced with Fiber-Reinforced Polymer (FRP) Bars

ACI 548.6R-96 Polymer Concrete-Structural Applications State-of-the-Art Report

ASTM D 648 (most current) Test Method for Deflection Temperature of Plastics Under Flexural Load in Edgewise Position.

ASTM D 6783 (most current) Standard Specification for Polymer Concrete Pipe.

ASTM D 2584 (most current) Test Method for Ignition Loss of Cured Reinforced Resins.

ASTM C 923 (most current) Standard Specifications for Resilient Connectors between Concrete Manholes Structures and Pipe.

ASTM C 990 (most current) Standard Specification for Joints for Concrete Pipe, Manholes and Precast Box Sections using Preformed Flexible Joint Sealants

ASTM C 497 (most current) Test Methods for Concrete Pipe, Manhole Sections, or Tile.

ASTM C 267 Standard Test Methods for Chemical Resistance of Mortars, Grouts, and Monolithic Surfaces & Polymer Concretes

1.03 SUBMITTALS

A. Conform to bid document requirements

B. Submit manufacturer’s data and details of following items for approval:

1. Shop drawings of structure sections, base units and construction details, jointing methods, materials, and dimensions

2. Summary of criteria used in design of structures including, at minimum, material properties, loading criteria, and dimensions assumed. Include certification from manufacturer that polymer concrete manhole design meets or exceeds the load and strength requirements of ASTM C 478 and ASTM C 857, reinforced in accordance with ACI 440.1R-15.

3. Frames, grates, vent pipes ring and covers, and other accessories as required by design

4. Materials to be used in fabricating pipe drop connections

5. Materials to be used for pipe connections

6. Materials to be used for stubs and stub plugs, if required

7. Proof of independent chemical resistance testing conducted in accordance with ASTM C 267

8. Current ISO 9001:2015 Certification for the facility where the polymer concrete structures are manufactured for the project.

9. References of 5 previous polymer concrete projects including scope in the last 5 years performed with both owner and contractor contact information for reference and review by owner. References of projects not being done by current company shall not be allowed.

10. 50 year corrosion warranty on the polymer concrete structures to be provided and enforced from contract completion date.

C. Submitted sealed drawings by a registered Professional Engineer in the state where installation is being performed

PART 2 PRODUCTS

2.01 POLYMER CONCRETE STRUCTURES

A. Provide polymer concrete manhole sections, monolithic base sections and related components referencing to ASTM C 478.

B. Provide base riser section with monolithic cast. Bench and invert channel and/or fillet shall be one continuous cast. No cold joints allowed.

a. For non-circular or large diameter structures with a “drop-in” channel or fillet split out for handling, the entire floor, bench, and walls may be separate components.

C. Provide riser sections joined with bell and spigot / ship-lap design seamed with butyl mastic and or rubber gaskets (ASTM C 990) so that on assembly, structure base, riser and top section make a continuous and uniform structure.

a. Grouted connections shall only be accepted as a secondary sealing method. Mastic and/or gaskets shall be required for each joint.

D. Construct riser components for polymer concrete structures from standard polymer concrete structure components of the diameter indicated on drawings.

Use various lengths of polymer concrete structure components in combination to provide correct height with the fewest joints

E. Design wall sections for depth and loading conditions with wall thickness as designed by polymer concrete manufacturer.

F. Provide tops to support AASHTO HS-20 loading or loads as required and receiving cast iron frame covers or hatches, as indicated on the drawings.

2.01-1 DESIGN CRITERIA:

Polymer Concrete structure components (risers, cones, flat lids, grade rings and base sections) shall be designed by manufacturer to meet the intent of ASTM C 478 with allowable compositional and sizing differences as designed by the polymer concrete manufacturer.

1. AASHTO HS-20 design or as required loading applied to structure cover and transition and base slabs

2. Polymer manholes will be designed based upon live and dead load criteria in ASTM C 857 and ACI 350-06.

3. Unit soil weight of 120 pcf located above portions of manhole, including base slab projections.

4. Internal liquid pressure based on unit weight of 63 pcf.

5. Dead load of structure sections fully supported by polymer concrete structure base.

6. Buoyancy calculations to be provided based on geotechnical report with a safety factor of at least 1.2, excluding skid friction.

7. Polymer Concrete Compressive Strength: Minimum of 9,000 psi conforming to ASTM C497

2.01-2 DESIGN:

Polymer Concrete structure risers, cones, flat lids, grade rings and manhole base sections shall be designed by manufacturer to meet loading requirements of ASTM C 478, ASTM C 857 and ACI 350-06 as modified for polymer concrete structure design as follows:

1. Polymer Concrete Mix Design shall consist of thermosetting resin, sand, and aggregate. No Portland cement shall be allowed as part of the mix design matrix. All sand and aggregate shall be inert in an acidic environment.

2. Reinforcement – Shall use acid resistant reinforcement (FRP Bar) in accordance with ACI 440.1R-06 as applicable for polymer concrete design

3. The wall thickness of polymer concrete structures shall not be less than that prescribed by the manufacturer’s design by less than 95% of stated design thickness

4. Each polymer concrete structure component shall be free of all defects that, due to their nature and degree or extent, detrimentally affect the strength and serviceability of the component part. Cosmetic defect shall not be cause for rejection. The nominal internal diameter of structure components shall not vary more than 2%. Variations in height of two opposite sides of risers and cones shall not be more the 5/8 inch. The under run in height of a riser or cone shall not be more than 3/8 inch.

5. Marking and Identification - Each structure shall be marked with the following information - Manufacturer’s name or trademark, Manufacturer’s location and Production Date.

6. Structure joints shall be assembled with a bell/spigot or shiplap butyl mastic and/or gasketed joint so that on assembly, manhole base, riser and top section make a continuous and uniform manhole. External joint sealants can be utilized as well in areas of high groundwater or needing additional containment. Joint sealing surfaces shall be free of dents, gouges and other surface irregularities that would affect joint integrity.

7. Minimum clearance between wall penetrations and joints shall be per manufacturer’s design

8. Construct invert channels to provide smooth flow transition with minimal disruption of flow at pipe-manhole connections. Invert slope through manhole is as indicated on drawings. All precast base sections to be cast monolithically. Polymer concrete structure bench and channel are to be constructed with all polymer concrete material.

9. Extended ballast slab for buoyancy collars can be addressed with cementitious concrete material.

10. Provide resilient connectors conforming to requirements of ASTM C 923 or other options as avaliable. All connectors are to be water tight. Install approved resilient connectors at each pipe entering and exiting manholes in accordance with manufacturer’s instructions.

2.01-3 QUALITY CONTROL

Facility Quality Control shall be maintained by adhearing to ISO 9001:2015 for manufacturing. All facility manufacturing polymer concrete shall be ISO 9001:2015 Certified, with current certification provided via submittals. All fabrication will take place in an all polymer concrete fabrication facility. At no time will the polymer concrete fabrication facility share the facility with a cementitious precast product production facility. Fabricator is also to provide references of 20 previous projects in the last 5 years performed with both owner and contractor contact information for reference and the scope and review by owner. References of projects not being done by current company shall not be allowed.

2.01-4 GROUTING

All materials needed for grouting and patching will be a polyester mortar compound provided by the manufacturer or an approved equal by the manufacturer.

http://www.armorock.com/