B09_Amd8_-_Spec_33_31_05_-_MANHOLE_LINING___REHABILITATION_0008.pdf

DEVA 318717 33 31 05 - 1

MANHOLE LINING AND REHABILITATION

SECTION 33 31 05 – MANHOLE LINING AND REHABILITATION

PART 1 - GENERAL

1.1 WORK OF THIS SECTION

A. This specification covers the work necessary to furnish and install a complete lining or rehabilitation system for sanitary sewer structures, as shown on the drawings and as specified herein. Work includes, but is not limited to, the following:

1. Stopping Leaks by repair and sealing of the concrete and/or masonry bench, channel, invert, pipe inlets, walls, cone, chimney and frame of all structures to include removal of unsound materials, preparation, chemical grouting, structural lining, patching, plugging and sealing compounds.

2. Surface preparation, and installation of Structural Lining, High Build Corrosion Protection

Lining and/or Flexible Chimney Seal to include protection of surfaces not to be treated, touch-up, clean-up, and appurtenant work all in accordance with the requirements of the

Contract Documents and this Specification.

1.2 REFERENCES

1. Without limiting the generality of other requirements of these specifications, all work hereunder shall conform to the applicable requirements of the referenced portions of the following documents, to the extent that the requirements therein are not in conflict with the provisions of this Section. All references and standards listed shall be the latest revisions.

Joint and individual documents are referenced.

a. SSPC – The Society for Protective Coatings

b. NACE – National Association of Corrosion Engineers

c. SSPC-SP 13/NACE No. 6 Surface Preparation of Concrete

d. SSPC-TU 2/NACE 6G197 Design, Installation, and Maintenance of Coating

Systems for Concrete Used in Secondary Containment

e. SSPC-SP 5/NACE No. 1, White Metal Blast Cleaning

f. SSPC-SP10/NACE No. 2, Near White Metal Blast Cleaning

g. SSPC-SP 6/NACE No. 3,Commercial Blast Cleaning

h. NACE RP0892 “Linings over Concrete for Immersion Service”

i. NACE Standard RP0591 “Coatings for Concrete Surfaces in Non-Immersion and

Atmospheric Service”

j. NACE SP0188 “Discontinuity Holiday Testing of Protective Coatings”.

k. NACE RP 6F-164 “Curing of Interior Tank Linings”.

l. NACE RP 6F-166 “Recommended Practice for Inspection of Linings on Steel and

Concrete”

m. ICRI – International Concrete Repair Institute

1) Technical Guideline No.03372, “Selecting and Specifying Concrete Surface

Preparation for Sealers, Coatings, and Polymer Overlays”

2) Technical Guideline No. 03731, “Guide for Selecting Application Methods for the Repair of Concrete Surfaces”

3) Technical Guideline No. 03730, “Guide for Surface Preparation for the Repair of Deteriorated Concrete Resulting from Reinforcing Steel Corrosion”

n. ASTM – American Society for Testing and Materials

1) ASTM E-337: Test Method for Measuring Humidity with a Psychrometer

DEVA 318717 33 31 05 - 2

2) ASTM D 4258 “Practice for Surface Cleaning Concrete for Coating”

3) ASTM D 4261 “Practice for Surface Cleaning Unit Masonry for Coating”

4) ASTM D 4262 “Test Method for pH of Chemically Cleaned or Etched

Concrete Surfaces”

5) ASTM D 4414 “Standard Practice for Measurement of Wet Film Thickness by Notch Gages”

6) ASTM D 4787 “Standard Practice for Continuity Verification of Liquid or

Sheet Linings Applied to Concrete Substrates”

7) ACI – American Concrete Institute

8) ACI 350-01 “Code Requirements for Environmental Engineering Concrete

Structures”

9) ACI 350.1 “Testing of Reinforced Concrete Structures for Water Tightness”

10) ACI 350.2 “Concrete Structures for Containment of Hazardous Material”

11) ACI 503 “Use of Epoxy Compounds with Concrete”

12) ACI 504 “Guide to Sealing Joints in Concrete Structures”

1.3 ACTION SUBMITTALS

1. Submit product data for each component specified including data substantiating that the proposed materials comply with specified requirements, and recommendations by the manufacturer covering all materials.

2. Submit qualifications

1.4 QUALITY ASSURANCE

1. Acceptable Manufacturers: The manufacturer of the specified products shall have in existence, for a minimum of three (3) years, a program of training, and technically supporting a nationally organized Approved Contractor Program. Manufacturer must provide five (5) project histories with names, dates, addresses, and phone numbers of contact persons for projects of similar scope, which have been completed at least three (3) or more years ago.

a. Submit manufacturer’s representative name, address and telephone number who will be available to provide information and suggestions on the proper use of the products.

2. Single Source Supply: All products described in Part 2.01 shall be manufactured by or approved for use by the manufacturer of the sanitary sewer infrastructure linings or rehabilitation system specified herein.

3. Installer Qualifications: Engage only factory trained, approved applicators that have successfully completed applications using specified materials on projects of similar size and scope.

a. Provide (3) three references with name, address, and telephone number.

b. Provide written approval from the material manufacturer.

c. All of the contractor’s jobsite personnel must be trained in the hazards associated with confined space entry. All personnel entering a confine space shall be certified for confined space entry.

4. Equipment Requirements

a. Application equipment must be approved in writing by the product manufacturer.

5. Substitutions

a. Manufacturers seeking approval of products other than the specified system must supply cured samples, full product information, project histories and references, technical data with specifications, MSDS and certifications regarding conformity of

DEVA 318717 33 31 05 - 3

performance properties from an independent testing laboratory. The product being submitted for approval must meet all requirements of the performance properties specified within this specification. Compliance with the above quality assurances must be provided in written form at least fourteen (14) days before bids are received.

Omission or non-conformance of any item will result in rejection of the request.

6. Pre-Installation Conference

a. The contractor, the installation sub-contractor, and the sanitary sewer infrastructure lining and rehabilitation system manufacturer’s representative shall meet on site with the Contracting Officer. Particular emphasis shall be placed on these specifications, safety, weather conditions, surface preparation, material application, and inspection.

b. The Contractor shall submit to the Contracting Officer any revisions or changes agreed upon, reasons thereof, and parties agreeing or disagreeing with them.

7. Substrate Conditions: Do not proceed with work until substrate preparation and tolerances have been approved by the Contracting Officer, sanitary sewer infrastructure lining and rehabilitation system manufacturer’s representative, the approved installation sub-contractor, and the Contractor.

B. DELIVER, STORAGE AND HANDLING

1. Deliver products to the job site in manufacturer’s original, unopened containers bearing manufacturer’s name and label and the following information

a. Product name

b. Product description (generic product classification)

c. Manufacturer’s lot number

d. Color

2. Store materials in sealed original manufacturer’s containers. Store materials in a protected area out of direct sunlight. Keep containers clean and undamaged. Adhere to manufacturer’s published storage temperature and shelf-life recommendations. Protect all materials from freezing.

1.5 CONTRACTOR QUALIFICATIONS

A. Contractor (or Sub-Contractor) shall provide documented evidence of successful installation of work comparable in nature to the scope of work required by this project for a minimum of two years.

PART 2 - PRODUCTS

2.1 Sanitary Sewer Infrastructure Lining or Rehabilitation System (Stopping Leaks, Structural

Lining, High Build Corrosion Protection Lining, Flexible Chimney Seal.

A. System

1. Structural Linings – Designated structures shall receive an application of cementitious

Structural Lining repair mortar. The structural lining repair mortars are classified as

Hydraulic Cements, Vertical Thin Patch, Microsilica Repair Mortars or Calcium

Aluminate Repair Mortars. Microsilica Repair Mortars shall be designated for areas of

Mild H2s content or areas to be topcoated with a corrosion resistant coating or lining as shown on the drawings. Calcium Aluminate Repair Mortars shall be designated for areas of moderate H2S content or areas to be top coated with corrosion-resistant coating or lining

DEVA 318717 33 31 05 - 4

as shown on the drawings. Thickness shall be sufficient to replace lost cross-section, fill voids and provide a minimum ½” cover over all interior concrete and masonry surfaces of the structure.

a. Hydraulic Cements Shall be cement based, quick setting, hydraulic cement compound which instantly stops weeping water through concrete or masonry walls and floors. They will become harder and more resistant when subjected to constant water pressure. (Used primarily for filling large voids and stopping minor weeping water leaks)

1) A.W. Cook Cement, CEMTEC Hydraulic Cement or equal salient characteristics:

a) Physical, Functional & Performance (28-day cure)

b) Compressive Strength ASTM C-109: 5,500 psi

c) Tensile Strength ASTM C-496: 650 psi

d) Bond Strength ASTM C-882 (Modified): 880 psi

e) Setting Times (Gilmore) “Hot Mix”: 65 seconds

b. Rapid Cure Vertical Grade repair mortars shall be a one part, polymer modified, fast setting, silica fume, fiber reinforced mortar designed for vertical and overhead repairs from ¼” to 2” in one lift. The product may be applied by hand trowel or sprayed with a low-pressure pump. (Used to hand place large voids, bench repair, or hand troweled structural wall linings)

1) A.W. Cook Cement, CEMTEC Silatec Rapid Cure Vertical Grade or equal salient characteristics:

a) Physical, Functional & Performance (28-day cure)

b) Compressive Strength ASTM C-109: 6,800 psi

c) Flexural Strength ASTM C-293: 990 psi

d) Bond Strength ASTM C-882 (Modified): 1,600 psi

e) Shrinkage ASTM C-596: 0.07%

f) Abrasion Resistance – ¼” APCI: 1

g) Setting Times @ 77°F

h) Initial Set – 35 min

i) Final Set – 50 min

c. Microsilica repair mortars shall be a blend of Portland cement, graded silica sand, fibers and silica fume. The mortar may be hand troweled or spray applied, usually from ½” to 1” in depth. Uses include repairing concrete walls, ceilings, lining brick or concrete manholes and lift stations, etc. Microsilica repair mortar provides an extremely dense matrix and will accept coatings at earlier ages than typical Portland cement repair products. (Used primarily for structural wall linings)

1) A.W. Cook Cement, CEMTEC Silatec MSM or equal salient characteristics:

a) Physical, Functional & Performance (28-day cure)

b) Compressive Strength ASTM C-109: 10,400 psi

c) Flexural Strength ASTM C-293 : 1,695 psi

d) Shrinkage ASTM C-596: 0.00%

e) Freeze/Thaw ASTM C-666 100 cycles: No Effect

f) Bond Strength ASTM C-882 (Modified): 1,695 psi

g) Modulus of Elasticity ASTM C-469: 4,533,333 psi

h) Tensile Strength ASTM C-496: 750 psi

d. Calcium Aluminate repair mortars shall be a blend of quartz silica, fibers and calcium aluminate cement. They can be hand troweled or spray applied, usually from

½” to 1” in depth. Uses include repairing concrete wall and ceilings, lining brick or concrete manholes, lift stations, etc. They can be especially useful when coatings

DEVA 318717 33 31 05 - 5

are required at early stages of cure. (Consult with coating manufacturer for specific times) (Used primarily for structural wall linings)

1) A.W. Cook Cement, CEMTEC Silatec CAM or equal salient characteristics:

a) Physical, Function & Performance:

b) (28-day cure)

c) Compressive Strength ASTM C-109: 12,800 psi

d) Flexural Strength ASTM C-293: 1,360 psi

e) Shrinkage ASTM C-596: 0.03%

f) Tensile Strength ASTM C-496: 650 psi

g) Freeze/Thaw, 300 cycles ASTM C-666: No Effect

h) Bond Strength ASTM C-882 (Modified): 1,765 psi

2.2 PERFORMANCE CRITERIA

A. The High Build Corrosion Protection Coating System shall consist of Sherwin-Williams Dura-

Plate 6100 Epoxy or equal salient characteristics. This is an ultra-high solids, high build, amine cured epoxy designed for the protection of concrete and steel in highly corrosive hydrogen sulfide

(microbial induced) environments associated with wastewater applications including lift stations, digesters, aeration basins, manholes and wet wells. The application thickness shall be 80 – 125 mils DFT, when applied to concrete, masonry or structural lining surfaces. The specified film thickness shall be applied via spray application in a single coat with multiple passes.

1. Physical, Function & Performance:

a. Adhesion – ASTM D4541: >2,000 psi, Concrete Failure

b. Abrasion Resistance: ASTM D4060, 1,000 g, 1000 cycles, CS- 17 Wheel – <90 mg loss

c. Compressive Strength: ASTM D695 – 15,000 psi

d. Durometer Hardness: ASTM D2240 - Shore D - 83

e. Flexural Modulus: ASTM D790 – 590,000 psi

f. Flexural Strength: ASTM D790 – 11,000 psi

g. Tensile Elongation: ASTM D638 – 4.8%

h. Tensile Strength: ASTM D638 – 5,600 psi

i. Chemical Resistance to Sulfuric Acid: 20% Concentration – No Effect

B. The Flexible Chimney Seal shall consist of Sherwin-Williams Envirolastic AR530 Chimney Seal

Cartridge System or equal salient characteristics. This is a 100% Volume Solids, High Build, Aromatic, Polyurea formulated for use in highly corrosive hydrogen sulfide (microbial induced corrosion) environments where a tough, flexible, impact resistant, waterproof, quick turn around chimney seal is required. The application thickness shall be 60 –125 mils DFT.

1. Physical, Function & Performance:

a. Abrasion Resistance – ASTM D4060, 1kg, 1000 cycles, CS-17 Wheel – 5 mg loss

b. Adhesion – ASTM D4541 – 350 psi, Concrete Failure

c. Coefficient of Linear Thermal Expansion – ASTM C531(in/in/°F) – 4 X 10(-5)

d. Impact – ASTM D2794 on steel panels – >160 in./lb, direct and indirect

e. Durometer Hardness – ASTM D2240 – Shore D 50

f. Elongation – ASTM D638 – 530%

g. Mandrel Bend – ASTM D522 – Pass

h. Tear Strength – ASTM D624 – 525 pli

i. Tensile Modulus – ASTM D638 – 100% Modulus – 1,400 psi; 300% Modulus –

1,800 psi

2. Tensile Strength – ASTM D638 – 2440 psi

DEVA 318717 33 31 05 - 6

PART 3 - EXECUTION

3.1 SURFACE PREPARATION

A. Inflow and Infiltration

1. Active leakage of all concrete and brick structures shall be stopped by trenchless technology method of chemical grouting with polyurethane grouts. Grouts shall be installed per manufacturers directions and could include any of the hydrophilic or hydrophobic products listed or combination thereof.

B. Concrete

1. The NACE/SSPC Joint Surface Preparation Standards for concrete surface preparation are incorporated in and made part of this specification. All references to SSPC SP-13/NACE

No 6 designate the definitions and other requirements in these documents. The

International Concrete Repair Institute (ICRI) Technical Guideline #03732, Guide to

Surface Preparation of Concrete to Receive Sealers, Coatings and Polymer Overlays shall be used to visually evaluate the concrete surface profile. Refer to manufacturers’ Concrete

Surface Preparation Guide.

2. Create a minimum surface profile for the system specified in accordance with the methods described in ICRI No. 03732 to achieve profile CSP-3 to CSP-5

3. Concrete surface defects, such as deteriorated concrete or masonry, hollow areas, bugholes, honeycombs, cracks and voids shall be filled flush and true with the specified structural lining compound in accordance with ICRI Technical Guide No 03730 “Guide for Selecting

Application Methods for the Repair of Concrete Surfaces”. Fins, trowel marks, and all protrusions or rough edges shall be removed. All active water leaks shall be stopped by use of polyurethane chemical grouting compounds.

4. Concrete Surface Repair: Surface voids and defects

a. Areas less than 1/2” deep shall be repaired with Rapid Cure Vertical Grade repair mortars or Hydraulic Cement.

b. Areas that are greater than 1/2” deep shall be repaired with specified structural lining repair mortar.

5. Provide a clean, saturated surface dry (SSD) concrete surface with no free standing or moving water, with a minimum surface profile as defined above. All substrates are to be vacuumed, swept and blown down with clean, dry air to remove spent abrasive, dust and other foreign material that might interfere with the adhesion of the primer and lining.

6. Debris resulting from surface preparation and cleaning shall not be allowed to enter any water streams and shall be removed form the structure.

C. Miscellaneous Metals

1. The NACE / SSPC Joint Surface Preparation Standards for abrasive blasting approved in

October 1994 are incorporated in and made a part of this specification. All references to

SSPC-SP6 / NACE No. 3 and SSPC-SP10 / NACE No. 2 designate the definitions and other requirements in these documents. SSPC VIS 1-89 Visual Standard for Abrasive Blast

Cleaned steel shall be used to visually evaluate the blast cleanliness.

2. Remove all oil and grease form surface by solvent cleaning per SSPC-SP1. Minimum surface preparation is SSPC-SP10 / NACE No. 2, Near White Metal Blast Cleaning.

Abrasive blast clean all surfaces using a sharp, angular abrasive for optimum surface profile (2-3 mils). Prime any bare steel the same day as it is cleaned and before flash

DEVA 318717 33 31 05 - 7

rusting occurs. Refer to manufacturers’ Guidelines Procedures for Surface Preparation of

Metals.

a. Inspect the surfaces to be lined. All holes in the steel surfaces or pits greater than

1/8 inch shall be repaired in accordance with the owner’s repair procedures.

b. All substrates are to be vacuumed, swept and blown down with clean, dry air to remove spent abrasive, dust and other foreign material that might interfere with the adhesion of the primer or basecoat.

c. The maximum allowable residual salt contamination, as measured with a KTA Scat

Kit or equivalent field test method, immediately prior to the application of the first coat is as follows:

1) 5 micrograms per square centimeter (50mg/m2) most commodities up to

120oF

d. Corrosion pits in the blasted steel shall be filled flush with the substrate with Steel-

Seam FT 910 patching and surfacing compound.

e. Projections and lap joints on welded plates and on riveted plates to be coated shall be filled with Steel-Seam FT 910 patching and surfacing compound in order to smooth out the surface and provide for a smooth transition of the lining over the substrate.

3.2 APPLICATION

A. The contractor shall, at all times, maintain traffic control measures in cooperation with local law enforcement, property owners and the municipality.

B. The contractor shall maintain sewer flows in accordance with the Contract Documents. Diversion of the flow or plugging the flow of sewerage for the purposes of affecting repairs to the structure shall be coordinated at direction of the Contracting Officer.

C. Comply with manufacturers’ written installation procedures and individual product data sheet application bulletins.

D. Apply materials in accordance with the following material coverage:

1. Corrosion Protection Coating System

Products Thickness (mils dft)

Repair/Patching and Structural Linings

Epoxy Repair/Resurfacer (Steel)/

Structural Lining Repair Mortars (Concrete) As Needed

Stopping Leaks As Needed

Primer

Not Required

Corrosion Protection Coating

Dura-Plate 6100 Epoxy 80.0-125.0

Total Targeted Thickness 80.0-125.0

DEVA 318717 33 31 05 - 8

2. Flexible Chimney Seal System

Products Thickness (mils dft)

Repair/Patching and Structural Linings

Epoxy Repair/Resurfacer (Steel)/

Structural Lining Repair Mortars (Concrete) As Needed

Stopping Leaks As Needed

Corrosion Protection Coating

Envirolastic AR530 Chimney Seal 60.0-125.0

Total Targeted Thickness 60.0-125.0

3.3 INSPECTION AND TESTING

A. The Contracting Officer will require the services of an independent testing laboratory to test the installed system. A holiday test also known as a spark test is required.

1. Minimum requirements of the corrosion protection coatings and/or lining system are that it be free of the following:

a. Uncured material

b. Inadequate thickness

c. Pinholes

d. Blisters

e. Delamination

f. Foreign matter

g. Unspecified materials

B. If test results indicate noncompliance with the specification, the following corrective action may be required of the Contractor:

1. Remove non-compliant systems or components.

2. Replace system or components in (1)

3. Assume the testing expenses.

3.4 PROTECTION

A. The corrosion protection coatings and/or lining system shall be protected from damage or detrimental elements during cure and until the time of final acceptance.

END OF SECTION 33 31 05