B09_Amd_4_Attach_2_33_31_13_-_Site_Sanitary_Sewerage_Gravity_Piping_0004.pdf

MORA 313019 / 331809 / 312439 33 31 13 - 1

SITE SANITARY SEWERAGE

GRAVITY PIPING

SECTION 33 31 13 – SITE SANITARY SEWERAGE GRAVITY PIPING

PART 1 - GENERAL

1.1 SECTION INCLUDES

A. Sanitary sewerage drainage piping, fittings, manholes, and accessories.

B. Connection of comfort station buildings sanitary sewer to sewer system.

C. Concrete manholes.

1.2 RELATED REQUIREMENTS

A. Section 03 30 00 – Cast-in-Place Concrete

B. Section 31 20 00 – Earth Moving

1.3 REFERENCE STANDARDS

A. ASTM C478 – Standard Specification for Precast Reinforced Concrete Manhole Sections.

B. ASTM D3212 – Standard Specification for Joints for Drain and Sewer Plastic Pipes Using

Flexible Elastomeric Seals.

C. ASTM D3261 – Standard Specification for Butt Heat Fusion Polyethylene (PE) Plastic Fitting for Polyethylene (PE) Plastic Pipe and Tubing.

D. ASTM D3350 – Standard Specification for Polyethylene Plastics Pipe and Fittings Materials.

E. ASTM F1055 – Standard Specification for Electrofusion Type Polyethylene Fittings for Outside

Diameter Controlled Polyethylene and Crosslinked Polyethylene (PEX) Pipe and Tubing.

F. ASTM F2620 – Standard Practice for Heat Fusion Joining of Polyethylene Pipe and Fittings.

G. AASHTO M306 – Standard Specification for Drainage, Sewer, Utility, and Related Castings.

1.4 SUBMITTALS

A. See Section 01 31 00 – Project Management & Coordination, for submittal procedures.

B. Product Data: Provide data indicating pipe, pipe accessories, manholes, and structural epoxy system.

C. Manufacturer’s Certificate: Certify that products meet or exceed specified requirements.

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D. Field Quality Control Submittals: Document results of field quality control testing.

E. Project Record Documents:

1. Record location of pipe runs, connections, manholes, rim elevations, and invert elevations.

2. Identify and describe unexpected variations to subsoil conditions or discovery of uncharted utilities.

PART 2 - PRODUCTS

2.1 SEWER PIPE

A. HDPE Pipe

1. Pipe shall be manufactured from resins meeting the requirements of ASTM D3350 with a cell classification of 445574C/E and a Plastic Pipe Institute (PPI) designation of PE 4710.

2. The pipes shall have a minimum standard dimension ratio (SDR) of 32.5.

3. HDPE shall have industry standard color marking for sewer line.

B. Fittings

1. Fittings shall be manufactured from the same resins and cell classification as the pipe unless specified otherwise. Butt fusion fittings and Flanged or Mechanical joint adapters shall have a manufacturing standard of ASTM D3261. Electro fusion fittings shall have a manufacturing standard of ASTM F1055.

C. Ductile Iron Pipe

1. Ductile iron pipe shall conform to AWWA C151 and ANSI A21.51. Ductile iron pipe shall have a cement mortar lining and a 1-mil thick seal coat meeting the requirements of

AWWA C104. Ductile iron pipe shall be Special Thickness Class 50. Non-restrained joints shall be either rubber gasket type, push on type, or mechanical type meeting the requirements of AWWA C111.

D. Ductile Iron Fittings

1. All fittings shall be the same material as the pipe being connected. Saddles fastened to pipe with external bands are not acceptable on new systems. Cast iron fittings may be used with ductile iron pipe. Fittings shall have sufficient strength to withstand handling and load stresses normally encountered.

2.2 PIPE ACCESSORIES

A. Tracer Wire: #12 AWG copper clad steel insulated wire

B. Warning Tape: Non-detectable, plastic, green in color, imprinted with “Caution Sewer Line

Below” or “Caution Sewer Line Buried Below” in large letters.

kevin.kraxberger Cloud

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2.3 PRECAST CONCRETE MANHOLE

A. Precast concrete manholes shall conform to ASTM C478-02.

B. Precast concrete manholes shall be manufactured with concrete having a minimum 28 day compressive strength, f’c equal to 4000psi.

C. Precast concrete manholes shall withstand HS-25 traffic loading.

D. The joints shall be the tongue and groove type.

2.4 MANHOLE RING AND COVER

A. Castings for manhole rings shall be gray iron or ductile iron and covers shall be ductile iron. Metal castings made from gray iron or ductile iron shall conform to the requirements of AASHTO

M306.

B. All mating surfaces shall be machine finished to ensure a nonrocking fit.

C. The inside recessed face of the ring and the vertical outside edge of the cover shall be machined or manufactured to the following tolerances:

1. Ring: +/- 3/32 inch

2. Covers: +/- 3/32 inch

D. All manhole rings and covers shall be identified by the name or symbol of the producing foundry and country of casting origin. The word “SEWER” shall be stamped or cast into cover so it is plainly visible.

2.5 STRUCTURAL EPOXY SYSTEM

A. Structural epoxy lining system must be a structural epoxy exhibiting the following features:

1. The structural epoxy must have undergone testing and verified by the US Environmental

Protection Agency’s, Environmental Technology Verification Program for Infrastructure

Rehabilitation Technologies (EPA ETV).

2. The structural epoxy must be 100% solid, no VOCs.

3. The structural epoxy must be a high flexural strength, fiber-filled system; a fiber-reinforced-polymer (FRP) formulates technology.

4. The structural epoxy must be self-priming, requiring no primer.

5. The structural epoxy must adhere to concrete with adhesion testing results in PSI that outperformed the cohesion of concrete on both dry concrete and wet brick (CIGMAT CT-

2/3).

6. The structural epoxy must be moisture tolerant up 100% and fully cure underwater.

7. The structural epoxy must withstand freeze-thaw and wet-dry cycles without causing adverse changes to the cure and performance properties.

8. The structural epoxy must be able to be applied by trowel (hand-applied) in order to mobilize and apply in limited access areas.

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9. The structural epoxy must hang with vertical and overhead thickness capability of 1/16 inch to 3/8 inch in one pass without sag.

10. The structural epoxy must have an indefinite recoat window without preparation for simple repair requirements.

11. The structural epoxy shall be resistant to all forms of chemical or bacteriological attack found in municipal sanitary sewer systems, including severe hydrogen sulfide (up to

800ppm).

12. The coating system must be a dense structural epoxy (epoxide) coating system (16,000psi or greater) exhibiting elongation (ASTM D2370) of 5% (minimum) to 10% (maximum) to ensure properties which withstand minor movement, vibration, and access induced mechanical impact.

13. Should the liner be installed in contact with drinking water, liner must be certified to

ANSI/NSF-61 standards.

B. Approved material shall exhibit the following physical properties:

1. Type: FRP-type, hybrid polymer (epoxy/epoxide)

2. Solids by Volume ASTM D2697: 100%

3. Solvent (VOC) ASTM D3960: none

4. Adhesion Strength (concrete, dry) CIGMAT CT-2/3: substrate failure

5. Adhesion Strength (brick, wet) CIGMAT CT-2/3: substrate failure

6. Adhesion Strength (steel) ASTM D4541: 1,500+ psi

7. Water Absorption ASTM D1653: < 0.1 g/sq.m.

8. Acid Exposure (pH 1, H2SO4) CIGMAT CT-1: passed

9. Tensile Strength ASTM D638: 5,500+ psi

10. Flexural Modulus ASTM D790: 500,000+ psi

11. Flexural Strength ASTM D790: 4,000+ psi

12. Compressive Strength ASTM D695: 16,000+ psi

13. Elongation ASTM D2370: 4-6%

14. Complete Cure: 18 hours (77F)

C. Active Leak Control

1. Active leak control materials are to be utilized to stop running water, infiltration, and other water stop needs.

2. All active leak control materials must be compatible with repair and lining materials.

3. Active leak control materials

a. Hydraulic cement

1) Quick setting, hydraulic cement compound designed for minor patching, and as a leak stopper and water plug, which stops running water and/or seepage through concrete.

2) Approved material shall exhibit the following physical properties:

a) Initial Set Time @ 77F 1-3 minutes

b) Tensile Strength, ASTM C-496 640+ psi

c) Compressive Strength, ASTM C-109

1 day ≥ 1,500 psi

28 days ≥ 5,000 psi

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b. Chemical grout

1) Chemical grout material used for grouting active leaks shall be injection hydrophobic polyurethane or equal.

2) While being injected, the chemical sealant must be able to react/perform in the presence of water.

3) The cured material must withstand submergence in water, without degradation.

4) The resultant sealant (grout) formation must be impervious to water penetration.

5) The final sealant must withstand freeze-thaw and wet-dry cycles without causing adverse changes to the sealant.

6) The final sealant formation must not be biodegradable.

7) Chemical grouting material final cure must not exceed one (1) hour.

8) Chemical grouting material must be compatible to other specified top coating and repair material and the final topcoat of the structural epoxy system.

D. Concrete Repair

1. Concrete repair methods include isolated, sectional, and fully restorative methods including brick, concrete, and other masonry filling, patching, termination of materials, seams, anchors, and rebuilding based on various conditions in order to repair imperfections that adversely affects flow, would compromise the structure and liner in the future, and to restore the structure to a profile accepting to the lining system.

2. Concrete patching and rebuilding

a. Concrete patching repair shall be performed for any spot repairs, filling or repairs of deep spalls, voids, gaps, bugholes/holes, and/or crevasses.

b. Rebuild isolated structures, inverts, benches and/or troughs, or other flow structures requiring build-up and/or rebuild in order to provide smooth flow transition waterway with no distortion of flow or connections.

c. Materials

1) The material is early-high strength, high build, sewer grade silica fume, fiber reinforced, industrial-grade modified mortar exhibiting the following minimum properties:

a) Flexural Strength, ASTM C-293 (28 days) ≥ 950 psi

b) Initial Cure < 24 hours

c) Tensile Strength, ASTM C-496 ≥ 300 psi

d) Bond Strength, ASTM C-882 (mod- 7 days) ≥ 800 psi

e) Shrinkage, ASTM C-596 < 0.05%

f) Freeze/Thaw, ASTM C666 100 cycles, no damage

3. Resurfacing

a. Concrete repair methods may also include resurfacing the substrate to create uniformity of the surface to accept coatings and to restore the substrate’s profile.

This will be required for any newly installed concrete structures to reduce the occurrences of outgassing, and for existing structures where degradation to substrate

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profile is greater than an ICRI CSP-6, and/or when the substrate requires restoration bringing profile to near-original.

b. Resurfacing thicknesses for existing structures, the thickness shall range between

1/4 inch and 1/2 inch (1/4” – 1/2”). For newly installed concrete structures, thicknesses shall be between 1/16 inch to 1/8 inch (1/16” – 1/8”). Should the substrate and structure require repair beyond half-inch, refer to Section 2.7.D.2.

“Concrete repair” for repairing materials beyond half-inch (1/2”) thickness.

c. Materials

1) The material is a fiber-reinforced, high build, corrosion resistant epoxy-modified-mortar, fortified with silica fume and micro silica. The hardened epoxy binder is dense and highly impermeable. The above performance is achieved by a complex formulation of mineral, organic resin and densifying agents and sophisticated chemical additives combined with next generation water-borne epoxy curing agents. Graded quartz sands are used to enhance particle packing and further improve the fluidity and hardened density. The composition also possesses excellent thin-section toughness, high modulus of elasticity and is self-bonding

2) The epoxy-modified-mortar shall exhibit excellent thin-section toughness and applied as low as 1/16 inch thickness, and capable of build-up up to 1-inch.

3) The epoxy-modified-mortar must be designed to accept the top coat structural epoxy at a minimum of two (2) hours after application at 77F.

4) The epoxy-modified-mortar can be applied by hand and/or wet-shot spray applied.

5) The epoxy-modified-mortar shall not require any further preparation or conditioning within 36 hours (at 77F) to accept structural epoxy top coat applications.

4. Exposed reinforcing bars

a. Exposed reinforcing bars must be treated with rust inhibiting primer, and encapsulated/patched with high density mortar.

b. Materials

1) Rust inhibiting primer must be epoxy-based, rust inhibiting primer designed for rapid curing, and for steel applications.

2) High density mortar patching will consist of any of the specified repair mortars within this section. Refer to Section 2.7.D.2. “Concrete repair” for repairing materials.

2.6 MORTARS AND GROUTS

A. Mortars and grouts shall be mixed in small quantities as needed and shall not be retempered or used after setting has begun.

B. Type 1 cement shall be in accordance with AASHTO M 85 except fineness for all Type 1 Portland cements shall not exceed 430m2/kg using Air permeability test. Maximum fineness limits do not apply if the sum of C3S + 4.75C3A is less than or equal to 90.

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C. Sand shall be clean and in accordance with Missouri Standard Specifications for Highway

Construction Section 1005.3 Fine Aggregate, except the minus No. 200 sieve requirement will not apply.

D. Water shall be in accordance with Missouri Standard Specifications for Highway Construction

Section 1070 Water.

E. Mortar used for grout shall consist of one part Type 1 Portland cement and three parts sand, by volume, mixed with sufficient water to form a grout of proper consistency.

PART 3 - EXECUTION

3.1 TRENCHING

A. See Utility Trenching in Section 31 20 00 and plan details for additional requirements.

3.2 INSTALLATION – PIPE

A. Verify that trench cut is ready to receive work and excavations, dimensions, and elevations are as indicated on layout drawings.

B. Install pipe, fittings, and accessories in accordance with manufacturer’s instructions.

C. Lay pipe to slope gradients noted on layout drawings; with maximum variation from true slope of 1/8 inch in 10 feet.

D. Connect to restroom building sanitary sewer outlet where indicated on contract plans.

E. Connect to existing sewer system where indicated on contract plans.

F. Install trace wire 6 inches above top of pipe; coordinate with Section 31 20 00.

G. Protect pipe and bedding cover from damage or displacement until backfilling operation is in progress.

3.3 INSTALLATION – JOINTS

A. HDPE pipe shall be joined into a continuous length by an approved joining method.

B. The joints shall not create an increase in the outside diameter of the pipe. The joints shall be fused, snap together, or threaded. The joints shall be watertight, rubber gasketed if applicable, and pressure testable to the requirements of ASTM D3212.

C. Joints to be welded by butt fusion shall meet the requirements of ASTM F2620 and the manufacturer’s recommendations. Fusion equipment used in the joining procedure shall be capable of meeting all conditions recommended by the pipe manufacturer, including, but not limited to, fusion temperature, alignment, and fusion pressure. All field welds shall be made with fusion equipment equipped with a Data Logger. Temperature, fusion pressure, and a graphic

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representation of the fusion cycle shall be part of the Quality Control records. Electro fusion may be used for field closures, as necessary. Joint strength shall be equal to or greater than the tensile strength of the pipe.

3.4 INSTALLATION – PRECAST CONCRETE MANHOLE

A. Store precast concrete sewer manholes at the project site in a manner to prevent physical damage and arranged so identification markings are visible.

B. Contractor shall be responsible for locating and protecting all existing utilities, structures, etc., whether indicated or not, which may be affected by the construction process.

C. The excavation for all manholes shall be sufficient to leave 1 foot in the clear between their outer surfaces and the earth bank.

D. All backfill shall be accomplished using approved material. Such material shall be free of debris, large stones, organic material, and other deleterious substances.

E. Precast elements shall be installed in accordance with the contract plans and approved shop drawings.

F. Lift and support precast sewer manholes only at designated lifting and/or support points.

G. All construction activities shall conform to applicable OSHA standards for safety.

H. The channels in manholes shall conform accurately to the sewer grade.

I. Ladder rungs shall be grouted in the precast concrete walls. Rungs shall be uniformly spaced at

12 inches and be vertically aligned.

J. In the event any pipe enters the manhole through the precast concrete units, the Contractor shall make the necessary cut through the manhole wall and steel mesh. The steel shall be cut flush with the face of the concrete and shall be cut in such a manner that it will not loosen the reinforcement in the manhole wall.

K. The ends of all pipes shall be trimmed flush with the inside walls.

L. Rubber gaskets or flexible plastic gaskets may be used in tongue and groove joints of precast units. Joints between precast manhole units used for sanitary sewers shall be rubber gasketed. All other joints and all openings cut through the walls shall be grouted and watertight.

M. If gaskets are used, handling of the precast units after the gasket has been affixed shall be done carefully to avoid disturbing or damaging the gasket or contaminating it with foreign material.

Care shall be exercised to attain proper alignment before the joints are entirely forced home.

During insertion of the tongue or spigot, the units shall be partially supported to minimize unequal lateral pressure on the gasket and to maintain concentricity until the gasket is properly positioned.

N. Flexible pipes connecting to sanitary sewer manholes shall be provided with an entry coupling or gasket. No pipe joint in flexible pipe shall be placed within 10 feet of the manhole. Backfilling will not be allowed until the concrete or mortar has thoroughly set.

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O. Manholes shall be watertight.

P. Manhole must pass vacuum test of 10hg; pre-testing prior to backfill is suggested. If pre-tested, concrete collar shall extend 2-inches below top of cone.

3.5 CONNECTIONS TO EXISTING MANHOLES

A. The Contractor shall verify invert elevations prior to construction.

B. The existing base shall be reshaped to provide a channel equivalent to that specified for a new manhole.

C. The Contractor shall excavate completely around the manhole to prevent unbalanced loading. The manhole shall be kept in operation at all times and the necessary precautions shall be taken to prevent debris or other material from entering the sewer, including a tight pipeline bypass through the existing channel if required. Water used for flushing and testing shall not be allowed to enter the sewer.

D. All damage to the manhole resulting from the Contractor’s operation shall be repaired at no expense to the Government.

3.6 SEWER CLEANOUTS

A. All cleanouts shall be extended to grade.

B. Cleanouts shall be full side sewer diameter and shall be plugged with a removable stopper which will prevent passage of dirt or water. The Contractor shall install an approved casting to provide ready access to the cleanout stopper.

3.7 STRUCTURAL EPOXY SYSTEM

A. General

1. All work shall be in strict accordance with the specifications and recommendation including application of all products as required and in accordance with manufacturer’s directions.

2. Contractor shall conform to all local, state and federal regulations including those set forth by OSHA, RCRA and the EPA and any other applicable authorities.

3. Products are to be kept dry, in a climate controlled environment, protected from weather and stored under cover. Products are to be stored and handled according to their safety data sheets. When freezing temperatures are expected in the area, the Contractor shall take measures to keep applied materials warm (as per manufacturer’s guidelines) and provide the required heat in the structure before repair work is started.

4. Any invert(s), channels, drains, or other openings shall be covered during construction operations to prevent loose materials from collection.

5. Bypassing and/or blocking of flow shall be done only with prior approval of the CO.

Contractor shall be responsible for transporting or pumping water to maintain operation of

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any flow, treatment, collection or distribution system while repairs or lining to structures are made.

6. Water will be available for the project to the Contractor as described in 01 50 00 Temporary

Facilities and Controls. Contractor shall be responsible for transporting the water.

7. It shall be the contactor’s responsibility to provide traffic control required by the particular location and/or jurisdiction.

8. Use approved equipment designed, recommended and/or manufactured by the material supplier specifically for the application of all materials.

9. Applicator shall initiate and enforce quality control procedures consistent with applicable

ICRI, NACE, and/or SSPC standards and the repair/coating manufacturer's recommendations.

10. Examination

a. Examine surface to receive rehabilitation prior to applying any materials. Notify

CO in writing if surfaces are not acceptable for rehabilitation and/or lining.

b. All structures to be repaired and coated shall be readily accessible to the Applicator.

c. Any active flows shall be dammed, plugged or bypassed as required to ensure that the liquid flow is maintained below the surfaces to be coated and that concrete to be coated has not reached moisture levels surpassing 90%. Flows should be totally plugged and/or diverted when coating any invert. All extraneous flows into the structures at or above the area coated shall be plugged and/or diverted until the structural epoxy coating has set hard to the touch.

d. Temperature of the surface to be coated must be maintained between 65F and 110F during application. Prior to and during application, care should be taken to avoid exposure of direct sunlight or other intense heat source to the structure being coated.

Specified surfaces should be shielded to avoid exposure of direct sunlight or other intense heat source. Where varying surface temperatures do exist, coating installation should be scheduled when the temperature is falling versus rising.

e. New Portland cement concrete structures shall have endured a minimum of 28 days since installation, prior to commencing epoxy structural coating installation.

f. Prior to commencing surface preparation, Contractor shall inspect all surfaces specified to receive the coating and notify CO, of any noticeable disparity in the site, structure or surfaces which may interfere with the work, use of materials or procedures as specified herein.

B. CLEANING AND PREPARATION OF SUBSTRATE

1. Surface preparation must be achieved immediately prior to utilizing any repair material and/or coatings; re-inspection and/or subsequent surface preparation may need to be repeated should conditions change after initial preparation.

2. All receiving surfaces shall be thoroughly cleaned and made free of all foreign materials including dirt, grit, roots, grease, sludge and all debris or material that may be attached to the substrate.

3. Surface preparation shall be performed on all specified surfaces to be lined or rehabilitated.

Unless otherwise noted, all newly installed concrete structures should first undergo curing of minimum 28 days prior to surface preparation and rehab/lining execution.

4. The objective of surface preparation is to produce a surface that is suitable for application and adhesion of the specified protective coating system and repair products.

a. Protrusions such as from burrs, sharp edges, fins, and concrete spatter shall be removed during surface preparation.

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b. Voids and other defects that are at or near the surface shall be exposed during surface preparation.

c. All concrete that is not sound shall be removed so that only sound concrete remains.

5. Surface preparation must achieve a clean and sound substrate in accordance with SSPC-

SP13/NACE No. 6 “Surface Preparation of Concrete.”

a. High pressure water cleaning or water jetting, and/or pre-approved dry or wet abrasive blasting may be necessary in order to achieve acceptable surface preparation free of all foreign material, laitance, oils, grease, incompatible existing coatings, waxes, form release, curing compounds, efflorescence, sealers, salts, and/or other contaminants.

b. An ICRI profile of CSP 3 or higher shall be achieved.

c. For existing structures, surface preparation shall yield a pH of 7 or higher.

d. No surface water or active leaks are to be present. Prepared concrete surfaces shall be tested for residual moisture after cleaning and drying, and prior to the application of the coating. Drying may be required with forced air and/or dry heat to achieve moisture levels below 80% prior to coating.

e. When grease and oil are present within the structure, an approved detergent or degreaser may be used integrally with the high pressure cleaning water if conditions dictate.

6. All materials resulting from the cleaning shall be caught at the base of each structure and removed prior to applying specified products.

7. All loose or defective concrete, mortar, brick, grout, ledges, steps and protruding ledges shall be removed to provide an accessible and uniformed surface prior to application of materials.

C. ACTIVE LEAK CONTROL PROCEDURE

1. When leaks are not readily identifiable upon cleaning operation, use blowers to dry interior for positive identification of leaks and weeping areas.

2. Hydraulic cement

a. The work consists of hand applying a dry quick-setting cementitious mix designed to instantly stop running water or seepage in all types of concrete and concrete structures. The certified applicator shall apply material in accordance with manufacturers’ recommendations.

b. The area to be repaired must be clean and free of all debris.

c. Proper applications should not require any special mixing of product or special curing requirements after application.

3. Chemical grout

a. Application of materials shall be by injection method only.

b. Mixing and handling of all the chemical grout materials shall be in strict accordance with manufacturer’s recommendations.

c. All excess chemical grout must be removed from the surface via mechanical grinding means and top patched with Hydraulic cement.

D. CONCRETE REPAIR METHODS

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1. All loose, cracked and corroded materials shall be removed from the area, exposing a sound substrate.

2. The materials shall be formed, trowel-applied, or shotcrete sprayed utilizing proper equipment on to specified surfaces. Follow instructions as published by the material manufacturer. If spraying, consult manufacturer for proper instruction and material version.

3. Concrete patching and rebuilding

a. Once cured, and before applying any lining system materials, refer to material specifications for post-cure preparation and readiness instructions. Follow mixing, application and handling instructions as written per materials product technical data sheets and SDS.

b. Apply materials and allow proper curing times prior to coating/lining.

4. Resurfacing

a. Follow mixing, application and handling instructions as written per materials product technical data sheets and SDS.

b. The mortar kits come pre-proportioned, for hand applications- use full kits as supplied, no do not any extra water.

c. For spray applications, water may be added, but limited, as specified by the

Manufacturer.

d. When mixed, a paste-like material will develop which may be troweled, sprayed, cast, pumped or gravity-flowed applied.

e. This mortar will harden quickly without any need for special curing. Therefore, execute finishing work by trowel immediately after applying or disbursing onto the substrate.

f. Either commence spraying or hand applying.

g. The epoxy-modified-mortar shall be applied at a 1/4 inch minimum, and 1/2 inch maximum (1/4” – 1/2”) for existing infrastructure. And between 1/16 inch and 1/8 inch (1/16” – 1/8”) for newly installed structures.

h. Finish with trowel.

i. Allow at least two (2) hours (77F) to cure, minimum, before applying the specified structural epoxy coating, but do not exceed thirty-six (36) hours. The window and condition to apply the structural epoxy coating remains open for 36 hours. Should this window expire, consult with manufacturer for written and approved guidance and instruction.

5. Exposed reinforcing bars

a. Prepare and clean via SSPC-SP 2 or 3 exposed reinforcing bars then clean with solvent (SSPC SP-1).

b. Treat with an epoxy-based, rapid-setting, rust inhibiting primer.

c. Allow primer to cure.

d. Patch with concrete patching materials as specified in “Concrete patching and rebuilding” section. Follow product and manufacturer execution specifications accordingly.

E. LINING METHOD AND PROCEDURE

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1. Application procedures shall conform to the recommendations of the structural epoxy coating manufacturer, including material handling, mixing, safety, and application equipment.

2. Top coating or additional coats of the structural epoxy coating should occur as soon as the prior coat becomes tack free, but no later than the recoat window for the specified material(s). Additional surface preparation procedures will be required if this recoat window is exceeded.

3. Follow all published and manufacturer recommended application methods.

4. If spraying, the Contractor must be certified to spray by the coating manufacturer verifying training and that the spray equipment is approved by the coating manufacturer, specifically designed to accurately ratio and condition the specified structural epoxy coating materials.

Refer to the manufacturers’ spray instruction and procedure prior to procuring material and applying any material in order to receive proper material variations and application considerations.

a. Apply at a minimum thickness of 100 mils DFT (0.1 inches).

5. If trowel-applied, properly mix and apply materials to all specified surfaces by hand-applied methods with trowel or trowel-type tools.

a. Combine 2 gallons kits, Part B to Part A of the packaged material, mix with a low-speed drill mixer for five (5) minutes until a homogenous blend is achieved.

b. Trowel the surface or section: for finishing, allow product to start initial gel (circa

30 minutes at 77F) and rub down with water to create a smooth, uniform finish.

c. Apply at a minimum thickness of 100 mils DFT (0.1 inches).

6. Allow 24 hours to cure.

F. QUALITY ASSURANCE AND ACCEPTANCE

1. Surface preparation inspection must take place prior to proceeding to material applications, this applies to both repair and lining applications.

a. Applicator must record, and submit to coating manufacturer’s representative or designated inspector:

1) pH level

2) Moisture content

3) Abrasive media type and/or preparation methods

4) ICRI conditions

2. During application, Applicator shall regularly perform and record epoxy coating thickness readings with a wet film thickness gage, such as those meeting ASTM D4414 - Standard

Practice for Measurement of Wet Film Thickness of Organic Coatings by Notched Gages or other type of measuring probe or similar, to ensure uniform thickness during application

3. Applicator shall perform holiday detection on all surfaces coated with the epoxy coating in the presence of the coating manufacturer’s representative or designated inspector. After the epoxy coating has set hard to the touch, surfaces shall first be dried, an induced holiday shall then be made on to the coated concrete surface and shall serve to determine the minimum/maximum voltage to be used to test the coating for holidays at that particular area. The spark tester shall be initially set at 100 volts per 1 mil (25 microns) of film

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thickness applied but may be adjusted as necessary to detect the induced holiday (refer to

NACE RPO188-99).

a. All detected holidays shall be marked by the designated inspector and repaired.

Additional epoxy coating material can be hand applied to the repair area. All touch-up/repair procedures shall follow the coating manufacturer's recommendations.

4. A final visual inspection shall be made by the Applicator and the coating manufacturer’s representative or designated inspector. Any deficiencies in the finished coating shall be marked and repaired by Applicator according to the procedures set forth herein.

3.8 FIELD QUALITY CONTROL

A. Perform field inspection and testing in accordance with Section 01 40 00.

B. Testing shall be conducted by Contractor or an independent testing and inspection agency employed by the Contractor.

C. If tests indicate Work does not meet specified requirements, remove Work, replace and retest at no cost to Government.

D. Visual Inspection

1. Contractor shall clean pipe of excess mortar, joint sealant and other dirt and debris prior to inspection.

2. Sewer shall be inspected by running a T.V. camera the full length of the line and recording on audio/visual media. Correct defects as determined by T.V. inspection including the presence of any misaligned, displaced, or broken pipe and the presence of visible infiltration or other defects. Sewer lateral locations shall be identified on the recording by distance from a manhole.

3. Correct defects as required. Any section with defects shall be re-inspected as described above.

E. Leakage Tests: A leakage test shall be performed on the full length of all sewer lines prior to acceptance.

1. Air Leakage Testing

a. Contractor shall perform air tests on all pipe 18″ and smaller.

b. Furnish all facilities required including necessary piping connections, test pumping equipment, pressure gauges, bulkheads, regulator to avoid over pressurization, and all miscellaneous items required.

1) The pipe plug for introducing air to the sewer line shall be equipped with two taps. One tap will be used to introduce air into the line being tested, through suitable valves and fittings, so that the input air may be regulated. The second tap will be fitted with valve and fittings to accept a pressure test gauge indicating internal pressure in the sewer pipe. An additional valve and fitting will be incorporated on the tap used to check internal pressure so that a second

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test gauge may be attached to the internal pressure tap. The pressure test gauge will also be used to indicate loss of air pressure due to leaks in the sewer line.

2) The pressure test gauge shall meet the following minimum specifications:

a) Size (diameter): 4-1/2 inches

b) Pressure Range: 0-15 P.S.I.

c) Figure Intervals: 1 P.S.I. Increments

d) Minor Subdivisions: 0.05 P.S.I.

e) Pressure Tube: Bourdon Tube or Diaphragm

f) Accuracy: +- 0.25% of maximum scale reading

g) Dial: White coated aluminum with black lettering, 270 deg. Arc and mirror edge.

h) Pipe Connection: Low Male 1.2″ N.P.T.

i) Calibration data will be supplied with all pressure test gauges.

Certification of pressure test gauge will be required from the gauge manufacturer. This certification data shall be up to date (within 1 year from test) will be available when tests are performed.

c. Test each reach of sewer pipe between manholes after completion of the installation of pipe and appurtenances and the backfill of sewer trench.

d. Plug ends of line and cap or plug all connections to withstand internal pressure. One of the plugs provided must have two taps for connecting equipment. After connecting air control equipment to the air hose, monitor air pressure so that internal pressure does not exceed 5.0 psig. After reaching 4.0 psig throttle the air supply to maintain between 4.0 and 3.5 psig for at least two (2) minutes in order to allow equilibrium between air temperature and pipe walls. During this time, check all plugs to detect any leakage. If plugs are found to leak, bleed off air, tighten plugs, and again begin supplying air. After temperature has stabilized, the pressured is allowed to decrease to 3.5 psig. At 3.5 psig, begin timing to determine the time required for pressure to drop from 3.5 psig to 2.5 psig. If the time, in seconds, for the air pressure to decrease from 3.5 psig to 2.5 psig is greater than that shown in the table below, the pipe shall be presumed free of defects.

Pipe Minimum Time Length for Time for Longer size (min:sec) Min. Time (ft) Length (sec)

4″ 3:46 597 .380 L

6″ 5:40 398 .854 L

8″ 7:34 298 1.520 L

10″ 9:26 239 2.374 L

12″ 11:20 199 3.418 L

If air test fails to meet above requirements, repeat test as necessary after all leaks and defects have been repaired. Prior to acceptance all constructed sewer lines shall satisfactorily pass the low pressure air test.

e. The height of groundwater above pipe in feet shall be divided by 2.3 to establish the pounds of pressure that will be added to all readings.

F. Deflection Test

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1. A deflection test shall be required on all installations after pipe has been laid and backfilled. The deflection test shall take place no sooner than 30 days after said pipe has been laid and backfilled. The maximum allowable deflection shall not exceed 5.0% of the pipe’s internal diameter.

2. The rigid ball or mandrel used for the deflection test shall have a diameter not less than ninety-five percent (95%) of the base inside diameter or average inside diameter of the pipe depending on which is specified in the ASTM specification, including the appendix, to which the pipe is manufactured. The test shall be performed without mechanical pulling devices. A mandrel must have nine (9) or more odd number of flutes or points.

The deflection test shall consist of guiding such a devise of the appropriate size for the pipe involved to accurately measure any deflection in the pipe. Attention is directed to the fact that the pipe’s nominal diameter is greater than the actual internal diameter of the pipe.

3. Upon completion of the testing, all piping showing a deflection greater than 5.0% shall be excavated, replaced, backfilled, and retested to the satisfaction of the CO.

END OF SECTION 33 31 13