486Star_URETEK-_4_LB_HDPF_Specification.pdf

ROADWAY AND RUNWAY PAVEMENT STRUCTURE AND FOUNDATION SOILS

STABILIZATION, AND LIFTING WHERE NECESSARY, UTILIZING A TWO-PART 1:1 BY

VOLUME, WATER RESISTANT, HIGH-DENSITY POLYURETHANE FOAM (HDPF)

DESCRIPTION:

This work shall consist of soil densification to strengthen base and sub-base soils under flexible asphalt, concrete, or composite pavement, and structures such as bridge approaches with sleeper slabs, by furnishing and injecting expansive polyurethane material into the foundation soils beneath the pavement through holes or injection tubes inserted into drilled holes at locations and depths, as shown on the plans or as directed by the Engineer, while monitoring for movement at the surface. If necessary, injection of material shall continue as needed to lift the pavement to grade.

MATERIAL:

1. High Density Polyurethane Foam.

Certify that the material conforms to the following requirements listed in this section:

PROPERTY TEST RESULTS

• Density, lbs./cu. ft. ASTM D-1622 3.5 - 4.5

• Compressive Strength, psi (min.) ASTM D-1621 55

• Tensile Strength, psi (min.) ASTM D-1623 90

• Shear Strength, psi (min.) ASTM C-273 45

• Flexural Strength, psi (min.) ASTM D-790 90

• Closed Cell content (%) ASTM D-1940 +85

HDPF shall reach 90% compressive strength within 30 minutes of injection. The material used shall be a two-part 1:1 by volume HDPF, such as URETEK 486 STAR. Other polyurethanes submitted must meet all of the required specifications and be preapproved by the Owner. The material shall be water blown, not chemically blown. The material shall be a polyurethane-forming mixture, having water insoluble diluents, which permits the formation of polyurethanes in the presence of water. Water insoluble diluents shall provide polyurethane foam with improved dimensional stability properties. The presence of water insoluble diluents and the characteristics and properties listed above must be certified by the manufacturer (paragraph 3). The certification from the polyurethane manufacturer must be submitted with the bid documents.

2. Aquatic and Terrestrial Toxicity Testing.

Polyurethane must pass aquatic and terrestrial toxicity testing and chemical analysis (RCRA metals, TOC, and COD). The polyurethane must show a lack of toxicity at 200 ppm TCLP leachate and show non-toxic for all test species. Testing must have been performed by an independent third-party testing laboratory. The certification from the independent third-party testing laboratory must be submitted with the bid documents.

3. Panel Test for Hydro-Insensitivity of High-Density Polyurethane Grout.

Polyurethane must pass the Panel Test for Hydro-Insensitivity of High-Density Polyurethane Grout (see the attached testing protocol). The Panel Test must be performed by an independent third-party testing laboratory, under the supervision and review of a licensed Professional Engineer, and must certify that the polyurethane material meets or exceeds the limits set forth in the panel test specification. The certification from the independent third-party testing laboratory must be submitted with the bid documents.

4. ASTM D1621 and ASTM D1622 Requirements.

Prior to beginning work and with the inspector observing, the Contractor must prepare 5 machine mixed field samples for density and compressive strength determination. The samples shall then be transported to an independent third-party testing laboratory at the Contractor’s expense. At the laboratory, a nominal 2” by 2” by 2” sample shall be taken from the center of each of the field samples and the density of the material shall be determined in accordance with ASTM D1622. The compressive strength shall then be determined by testing in accordance with ASTM D1621.

The Contractor shall submit electronic copies to the Owner’s Representative of the stress strain curves (ASTM D1621 showing force, lbs. vs. deflection, %) as well as density calculations, including measured specimen dimensions (ASTM D1622) for each specimen tested. Field samples shall be prepared and sent for testing for each individual batch/lot number of resin component used on the project.

The compressive strength and density determined from ASTM D1621 and ASTM D1622 shall be used to determine the percent of pay for this item as outlined in Measurement and Payment.

5. Non-shrink grout to patch drill holes.

Non-shrink grout must be supplied by a manufacturer on the approved products list and must be used within the shelf life and temperature limitation set by the manufacturer.

PRE-BID SITE VISIT:

All proposals and responses require the contractor to conduct a site visit prior to submitting a bid. The pre-bid site visit must be coordinated by the Owner’s Representative.

EQUIPMENT:

1. Portable Dynamic Cone Penetrometer (DCP).

Provide a portable DCP for on-site soils investigation to assist in location and depth of weak foundation soils and determination of correct injection pattern and injection elevations through tubes to densify weak soils.

The DCP must be a Pagani DPM 30 or similar, capable of taking readings up to 30 feet below grade. DCP testing may be required, as directed by the Owner’s Representative, to confirm existing sub-grade soil conditions. The name, model number, and description of the DCP unit(s) intended for use must be submitted with the bid documents.

2. Pumping Units.

Ensure that all pumping units used are equipped with certified flow meters to precisely measure the amount of each component injected, so that the 1:1 ratio by volume is maintained for quality control and a certified volume of injected polyurethane material is obtained for proper payment. Flow meters must be recertified annually (once every 12 months) to ensure accuracy. Certifications from the manufacturer (or an independent third party) demonstrating that each flow meter intended for use has been tested within the past 12 months must be submitted with the bid documents.

QUALITY MANAGEMENT:

1. Drilling Holes and Installation of Injection Tubes.

Drill injection holes in the pattern shown on the Standard Drawings, or as indicated on the approved field Quality Control (QC) plan, as approved by the Owner’s Representative. Drill 5/8” to 2” diameter holes, vertical and round, and to a depth indicated on the approved field QC plan. Install injection tubes to the prescribed injection depth(s). Tubes must be pushed a minimum of 4” below the grade of the road and/or runway prior to the commencement of injections.

2. Injection of the HDPF.

Inject the HDPF through holes, via injection tubes when needed, to fill voids and into the foundation soils beneath the pavement to the prescribed injection depth(s). Continuously monitor for movement of the structure. Foundations soils are sufficiently stabilized when movement of the structure is detected. If necessary, injection of material shall continue as needed to lift the pavement to grade.

3. Hole Patching.

Install a rapid set, non-shrink patching material into the drilled-out hole and strike patches flush with the surface of the surrounding pavement.

EXPERIENCE:

Have a minimum 3 years of experience injecting 1:1 by volume, two-part, expansive polyurethane through holes or tubes into soils while monitoring at the surface of the pavement for movement to demonstrate sufficient densification of the soils. Evidence of prior experience must be submitted with the bid documents: 5 awarded contracts within each of the previous 3 years.

Have as an employee of the company, a licensed Professional Engineer (P.E.) with a minimum of 3 years of experience in stabilization of pavement foundation soils by injecting 1:1 by volume, two-part, expansive polyurethane through holes or tubes into soils while monitoring at the surface of the pavement for movement to demonstrate sufficient densification of the soils. The name, hire date, and resume of the licensed Professional Engineer must be submitted with the bid documents.

MEASUREMENT AND PAYMENT:

HDPF will be measured to the nearest pound as displayed by the certified flow meter and paid for at the adjusted contract unit price per pound of polyurethane injected, including all materials, tools, equipment, labor, warranty, and incidentals necessary to perform the work.

Payment per pound shall be determined and/or adjusted per each of the tables below. 1

Payment Adjustment for Hydro-Insensitivity Panel Test

Hydro-Insensitivity Panel Test verified by 3rd party testing laboratory Pass Fail

Contractor does not provide 2

% Pay 100% 50% 50%

Payment Adjustment for Density

Density, lb./cu. ft. < 3.5 3.5 to 4.5 >4.5

% Pay 0% 100% See formula below 3

Payment Adjustment for Unconfined Compressive Strength

Unconfined Compressive Strength, psi

< 55 ≥ 55

% Pay 0% 3 100%

1 The total payment will be the lowest of the percent payments for density and compressive strength per individual batch/lot number used on the project or Pass/Fail of the Hydro-Insensitivity Panel Test.

2 If the Contractor does not provide the Panel Test for Hydro-Insensitivity of High-Density Polyurethane Grout (Material – paragraph 3) that is verified PASS/SATISFACTORY by an independent third-party testing laboratory, final payment per pound will be reduced by 50%.

3 The adjustment in pay for density and compressive strength shall be applied to the pounds of material used as based on the unit price of the polyurethane material indicated by batch/lot number.

Percent Pay = (4.5 / Density) * 100 Density = average density (lb./cu. ft.) per individual batch/lot number per ASTM D1622 (round to 1 decimal place)

WARRANTY:

Provide a two-year unconditional warranty against settlement of more than 1/2” of the injected areas. If movement of more than 1/2” in the injected areas occurs, the Contractor will return to inject the affected area to lift to proper grade at no charge to the owner.

DOCUMENT SUBMITTALS - to be included in the Quote/Bid Submission:

1. Certification by the manufacturer that the polyurethane to be used meets all the requirements in the

MATERIAL section, including that it is a 1:1 by volume, two-part, water blown polyurethane.

2. Toxicity Testing Results by an independent laboratory demonstrating that the polyurethane shows a lack of toxicity at 200 ppm TCLP leachate and show non-toxic for all test species.

3. Certification by a third-party testing lab that the polyurethane has passed the Panel Test for Hydro- Insensitivity of High-Density Polyurethane Grout confirming that the polyurethane is effective in wet or dry conditions.

4. Name, model number, and a description of the DCP unit(s) intended for use on projects.

5. Certifications from the manufacturer (or an independent third party) demonstrating that each flow meter intended for use has been tested within the past 12 months.

6. Evidence of prior experience: 5 awarded contracts within each of the previous 3 years injecting 1:1 by volume, two-part, expansive polyurethane through holes or tubes into soils while monitoring at the surface of the pavement for movement to demonstrate sufficient densification of the soils.

7. Name, hire date, and resume of the licensed Professional Engineer (P.E.) employed by the Contractor with a minimum of 3 years of experience in injecting 1:1 by volume, two-part, expansive polyurethane through holes or tubes into soils while monitoring at the surface of the pavement for movement to demonstrate sufficient densification of the soils.