Addendums

BENTOMAT® ST

CERTIFIED PROPERTIES

CETCO® Bentomat® ST is a reinforced geosynthetic clay liner (GCL) consisting of a layer of sodium bentonite between a polypropylene woven geotextile and a polypropylene nonwoven geotextile, which are needle-punched together.

MATERIAL PROPERT Y TEST METHOD TEST FREQUENCY CERTIFIED VALUES

Woven Base Geotextile Mass/Area1

ASTM D5261 200,000 ft2 (20,000 m2) 3.2 oz/yd2 (108 g/m2) min.

Nonwoven Cap Geotextile Mass/Area1 ASTM D5261 200,000 ft2 (20,000 m2) 6.0 oz/yd2 (203 g/m2) min.

Bentonite Moisture Content2 ASTM D2216 1 per 50 tonnes 12% max.

Bentonite Swell Index2 ASTM D5890 1 per 50 tonnes 24 mL/2g min.

Bentonite Fluid Loss2 ASTM D5891 1 per 50 tonnes 18 mL max.

Bentonite Mass/Area3 ASTM D5993 40,000 ft2 (4,000 m2) 0.75 lb/ft2 (3.7 kg/m2) min.

Total Mass/Area3 ASTM D5993 40,000 ft2 (4,000 m2) 0.81 lb/ft2 (4.0 kg/m2) min.

GCL Moisture Content ASTM D5993 40,000 ft2 (4,000 m2) 35% max.

GCL Grab Strength4 ASTM D6768 200,000 ft2 (20,000 m2) 30 lbs/in (5.3 kN/m) min.

GCL Peel Strength ASTM D6496 40,000 ft2 (4,000 m2) 3.5 lbs/in (610 N/m) min.

GCL Hydraulic Conductivity5 ASTM D5887 250,000 ft2 (25,000 m2) 5 x 10-11 m/s max.

GCL Index Flux5 ASTM D5887 250,000 ft2 (25,000 m2) 1 x 10-8 m3/m2/s max.

GCL Hydrated Internal Shear Strength6 ASTM D6243 1,000,000 ft2 (100,000 m2) 500 psf (24 kPa) typ.@ 200 psf (9.6 kPa)

Bentonite Durability7,9 GRI-GCL3 §5.6.1 Yearly 1 x 10-8 m/s max. @ 5 psi (35 kPa)

5 x 10-10 m/s max. @ 70 psi (500 kPa)

Base and Cap Geotextile Durability1,8,9 GRI-GCL3 §5.6.2 Yearly 65% retained min.

Notes:

1 Geotextile property tests performed on the geotextile components before they are incorporated into the finished GCL product.

2 Bentonite property tests performed before the bentonite is incorporated into the finished GCL product.

3 Reported at 0% moisture content.

4 All tensile strength testing is performed in the machine direction using ASTM D6768.

5 Index flux and hydraulic conductivity testing with deaired distilled/deionized water at 80 psi (550 kPa) cell pressure, 77 psi (530 kPa) headwater pressure and 75 psi (515 kPa) tailwater pressure.

6 Peak values measured at 200 psf (9.6 kPa) normal stress for a specimen hydrated for 48 hours. Site-specific materials, GCL products, and test conditions must be used to verify internal and interface strength of the proposed design.

7 Testing performed yearly for GCL manufactured with a woven base geotextile and nonwoven cap geotextile. The GCL test specimen is hydrated with distilled, deionized water prior to testing with a 0.1M CaCl2 solution at 5 psi (35 kPa) and 70 psi (500 kPa) normal pressures via ASTM D6766 in accordance with paragraph 5.6.1 of GRI-GCL3, rev. 4, dated March 28, 2016.

8 Base and cap geotextile test specimens are oven-aged for 50 days at 60°C prior to testing for tensile strength in accordance with paragraph 5.6.2 of GRI- GCL3, rev. 4, dated March 28, 2016.

9 Yearly testing results can be provided upon request.

TR 401-BST D5889/GRI-GCL3

05/2018

BENTOMAT® 200R

CERTIFIED PROPERTIES

CETCO® Bentomat® 200R is a reinforced geosynthetic clay liner (GCL) consisting of a layer of sodium bentonite between a polypropylene woven geotextile and a polypropylene nonwoven geotextile, which are needle-punched together.

MATERIAL PROPERT Y TEST METHOD TEST FREQUENCY CERTIFIED VALUES

Woven Base Geotextile Mass/Area1 ASTM D5261 200,000 ft2 (20,000 m2) 3.2 oz/yd2 (108 g/m2) min.

Nonwoven Cap Geotextile Mass/Area1

ASTM D5261 200,000 ft2 (20,000 m2) 3.0 oz/yd2 (100 g/m2) min.

Bentonite Moisture Content2 ASTM D2216 1 per 50 tonnes 12% max.

Bentonite Swell Index2 ASTM D5890 1 per 50 tonnes 24 mL/2g min.

Bentonite Fluid Loss2 ASTM D5891 1 per 50 tonnes 18 mL max.

Bentonite Mass/Area3 ASTM D5993 40,000 ft2 (4,000 m2) 0.75 lb/ft2 (3.7 kg/m2) min.

Total Mass/Area3 ASTM D5993 40,000 ft2 (4,000 m2) 0.79 lb/ft2 (3.9 kg/m2) min.

GCL Moisture Content ASTM D5993 40,000 ft2 (4,000 m2) 35% max.

GCL Grab Strength4 ASTM D6768 200,000 ft2 (20,000 m2) 30 lbs/in (5.3 kN/m) min.

GCL Peel Strength ASTM D6496 40,000 ft2 (4,000 m2) 1.0 lbs/in (175 N/m) min.

GCL Hydraulic Conductivity5 ASTM D5887 250,000 ft2 (25,000 m2) 5 x 10-11 m/s max.

GCL Index Flux5 ASTM D5887 250,000 ft2 (25,000 m2) 1 x 10-8 m3/m2/s max.

GCL Hydrated Internal Shear Strength6 ASTM D6243 1,000,000 ft2 (100,000 m2) 150 psf (7.2 kPa) typ.@ 200 psf (9.6 kPa)

Bentonite Durability7,9 GRI-GCL3 §5.6.1 Yearly 1 x 10-8 m/s max. @ 5 psi (35 kPa) 5 x 10-10 m/s max. @ 70 psi (500 kPa)

Base and Cap Geotextile Durability1,8,9 GRI-GCL3 §5.6.2 Yearly 65% retained min.

Notes:

1 Geotextile property tests performed on the geotextile components before they are incorporated into the finished GCL product.

2 Bentonite property tests performed before the bentonite is incorporated into the finished GCL product.

3 Reported at 0 percent moisture content.

4 All tensile strength testing is performed in the machine direction using ASTM D6768.

5 Index flux and hydraulic conductivity testing with deaired distilled/deionized water at 80 psi (550 kPa) cell pressure, 77 psi (530 kPa) headwater pressure and 75 psi (515 kPa) tailwater pressure.

6 Peak values measured at 200 psf (9.6 kPa) normal stress for a specimen hydrated for 48 hours. Site-specific materials, GCL products, and test conditions must be used to verify internal and interface strength of the proposed design.

7 Testing performed yearly for GCL manufactured with a woven base geotextile and nonwoven cap geotextile. The GCL test specimen is hydrated with distilled, deionized water prior to testing with a 0.1M CaCl2 solution at 5 psi (35 kPa) and 70 psi (500 kPa) normal pressures via ASTM D6766 in accordance with paragraph 5.6.1 of GRI-GCL3, rev. 4, dated March 28, 2016.

8 Base and cap geotextile test specimens are oven-aged for 50 days at 60°C prior to testing for tensile strength in accordance with paragraph 5.6.2 of GRI- GCL3, rev. 4, dated March 28, 2016.

9 Yearly testing results can be provided upon request.

TR 401-B200R D5889/GRI-GCL3

10/2017

L I N I N G T EC H N O LO G I E S | REM ED I AT I O N T EC H N O LO G I E S | D R I L L I N G SY S T EM S | B U I L D I N G EN V ELO P E | C O N T R AC T I N G S ER V I C E S

BENTOMAT® INSTALLATION GUIDELINES

GEOSYNTHETIC CLAY LINERS

- 2 -

BENTOMAT®

I N S TA L L AT I O N G U I D E L I N E S

GEOSYNTHETIC CLAY LINERS

2870 Forbs Avenue Hoffman Estates, IL 60192

847.851.1800 | 800.527.9948

CONTENTS

1. Introduction

2. Equipment Requirements

3. Shipping, Unloading, and Storage

4. Subgrade Preparation

5. Installation

6. Anchorage

7. Seaming

8. Sealing Around Penetrations and Structures

9. Damage Repair

10. Cover Placement

11. Hydration

NOTICE: THIS DOCUMENT IS INTENDED FOR USE AS A GENERAL GUIDELINE FOR THE INSTALLATION OF CETCO GCLS.

THE INFORMATION AND DATA CONTAINED HEREIN ARE BELIEVED TO BE ACCURATE AND RELIABLE. CETCO MAKES NO WARRANTY OF ANY KIND AND ACCEPTS NO RESPONSIBILITY FOR THE RESULTS OBTAINED THROUGH APPLICATION OF THIS INFORMATION. INSTALLATION GUIDELINES ARE SUBJECT TO PERIODIC CHANGES. PLEASE CONSULT OUR

WEBSITE @ WWW.CETCO.COM/LT FOR THE MOST RECENT VERSION.

www.CETCO.com

SECTION 1

INTRODUCTION

1.1 This document provides procedures for the installation of CETCO GCLs in a manner that maximizes safety, efficiency, and the physical integrity of the GCL.

1.2 These guidelines are based upon many years of experience at a variety of sites and should be generally applicable to any type of lining project using CETCO GCLs. Variance from these guidelines is at the engineer’s discretion.

1.3 The performance of the GCL is wholly dependent on the quality of its installation. It is the installer’s responsibility to adhere to these guidelines, and to the project specifications and drawings as closely as possible. It is the engineer’s and owner’s responsibility to provide construction quality assurance (CQA) for the installation. This will ensure that the installation has been executed properly. This document covers only installation procedures.

1.4 For additional guidance, refer to ASTM D5888 (Standard Guide For Storage and Handling of Geosynthetic Clay Liners) and ASTM D 6102 (Standard Guide For Installation of Geosynthetic Clay Liners).

SECTION 2

EQUIPMENT REQUIREMENTS

2.1 CETCO GCLs are delivered in rolls typically 2,600-2,950 lbs (1180-1340 kg). Roll dimensions and weights will vary with the dimensions of the product ordered. It is necessary to support this weight using an appropriate core pipe, as indicated in Table

1. For any installation, the core pipe must not deflect more than 3 inches (75 mm), as measured from end to midpoint when a full GCL roll is lifted.

2.2 Lifting chains or straps appropriately rated should be used in combination with a spreader bar made from an I-beam, as shown in Figure 1.

2.3 The spreader bar ensures that lifting chains or straps do not chafe against the ends of the GCL roll, allowing it to rotate freely during installation. Spreader bar and core pipe kits are available through CETCO.

2.4 A front end loader, backhoe, dozer, or other equipment can be utilized with the spreader bar and core pipe or slings. Alternatively, a forklift with a “stinger” attachment may be used for on-site handling. A forklift without a stinger attachment should not be used to lift or handle the GCL rolls. Stinger attachments (Figures 2-4) are specially fabricated to fit various forklift makes and models.

Table 1: Core Requirements

Product Nominal GCL Roll Size Lenth X Diameter Typical GCL Roll Weight Interior Core Size Core Pipe Length x Diameter Minimum Core Pipe

Strength

BENTOMAT DN, SDN 16’ x 24” (4.9 m x 610 mm) 2,650 lbs. (1204 kg) 3 3/4“ (100 mm) 20’ x 3.5” O.D. (6.1 m x 89 mm) XXH

BENTOMAT ST 16’ x 24” (4.9 m x 610 mm) 2,650 lbs. (1204 kg) 3 3/4“ (100 mm) 20’ x 3.5” O.D. (6.1 m x 89 mm) XXH

BENTOMAT STM 16’ x 32” (4.9 m x 814 mm) 2,500 lbs. (1130 kg) 3 3/4“ (100 mm) 20’ x 3.5” O.D. (6.1 m x 89 mm) XXH

BENTOMAT 200R 16’ x 24” (4.9 m x 610 mm) 2,650 lbs. (1204 kg) 3 3/4“ (100 mm) 20’ x 3.5” O.D. (6.1 m x 89 mm) XXH

BENTOMAT CLT 16’ x 26” (4.9 m x 660 mm) 2,650 lbs. (1204 kg) 3 3/4“ (100 mm) 20’ x 3.5” O.D. (6.1 m x 89 mm) XXH

BENTOMAT CL 16’ x 25” (4.9 m x 635 mm) 2,650 lbs. (1204 kg) 3 3/4“ (100 mm) 20’ x 3.5” O.D. (6.1 m x 89 mm) XXH

BENTOMAT 600 CL 16’ x 25” (4.9 m x 635 mm) 2,700 lbs. (1227 kg) 3 3/4“ (100 mm) 20’ x 3.5” O.D. (6.1 m x 89 mm) XXH

- 4 -

I N S TA L L AT I O N G U I D E L I N E S

GEOSYNTHETIC CLAY LINERS

2870 Forbs Avenue Hoffman Estates, IL 60192

847.851.1800 | 800.527.9948

FIGURE 1 -SPREADER BAR ASSEMBLY

2.5 When installing over certain geosynthetic materials, a 4 wheel, all-terrain vehicle (ATV) can be used to deploy the GCL. An ATV can be driven directly on the GCL provided that no sudden stops, starts, or turns are made.

2.6 Additional equipment needed for installation of CETCO GCLs includes:

panel by hand)

2.7 The CETCO EASY ROLLER™ GCL Deployment System is a preferred method of installing geosynthetic clay liners. Use of the EASY ROLLER system eliminates the need for spreader bars and heavy core pipes. Installation speed and worker safety are also significantly increased. For further details, contact CETCO.

FIGURE 2 - HOOK MOUNT

FIGURE 3 - FORK MOUNT (WITH FORK POCKETS)

FIGURE 4 - PIN MOUNT

SECTION 3

SHIPPING, UNLOADING, &

STORAGE

3.1 All lot and roll numbers should be recorded and compared to the packing list. Each roll of GCL should also be visually inspected during unloading to determine if any packaging has been damaged. Damage, whether obvious or suspected, should be recorded and the affected rolls marked.

3.2 Major damage suspected to have occurred during transit should be reported to the carrier and to CETCO immediately. The nature of the damage should also be indicated on the bill of lading, with specific lot and roll numbers noted. Accumulation of some moisture within roll packaging is normal and does not damage the product.

3.3 The party directly responsible for unloading the GCL should refer to this manual prior to shipment to ascertain the appropriateness of their unloading equipment and procedures. Unloading and on-site handling of the GCL should be supervised.

3.4 In most cases, CETCO GCLs are delivered on flatbed trucks.

There are three methods of unloading: core pipe and spreader bar, slings, or stinger bar. To unload the rolls from the flat-bed using a core pipe and spreader bar, first insert the core pipe through the core tube. Secure the lifting chains or straps to each end of the core pipe and to the spreader bar mounted on the lifting equipment. Hoist the roll straight up and make sure its weight is evenly distributed so that it does not tilt or sway when lifted.

3.5 All CETCO GCLs are delivered with two 2’x 12’ (50 mm x 3.65

mm) Type V polyester endless slings on each roll. Before lifting, check the position of the slings. Each sling should be tied off in the choke position, approximately one third (1/3) from the end of the roll. Hoist the roll straight up so that it does not tilt or sway when lifted.

3.6 In some cases, GCL rolls will be stacked in three pyramids on flatbed trucks. If slings are not used, rolls will require unloading with a stinger bar and extendible boom fork lift. Spreader bars will not work in this situation because of the limited access between the stacks of GCL. Three types of stingers are available from CETCO, a hook mount, fork mount and pin mount (Figures 2-4). To unload, guide the stinger through the core tube before lifting the GCL roll and removing the truck.

3.7 An extendable boom fork lift with a stinger bar is required for unloading vans. Rolls in the nose and center of the van should first be carefully pulled toward the door using the slings provided on the rolls.

3.8 Rolls should be stored at the job site away from high-traffic areas but sufficiently close to the active work area to minimize handling. The designated storage area should be flat, dry, and stable. Moisture protection of the GCL is provided by its packaging; however, based on expected weather conditions, an additional tarpaulin or plastic sheet may be required for added protection during prolonged outdoor storage.

3.9 Rolls should be stacked in a manner that prevents them from sliding or rolling. This can be accomplished by chocking the bottom layer of rolls. Rolls should be stacked no higher than the height at which they can be safely handled by laborers (typically no higher than four layers of rolls). Rolls should never be stacked on end.

SECTION 4

SUBGRADE PREPARATION

4.1 Subgrade surfaces consisting of granular soils or gravels are not acceptable due to their large void fraction and puncture potential. In applications where the GCL is the only barrier, subgrade soils should have a particle-size distribution of at least 80 percent finer than the #60 sieve (0.25 mm). In other applications, subgrade soils should range between fines and 1 inch (25 mm). In high-head applications (greater than 1 foot or

30.48 cm), CETCO recommends a membrane-laminated GCL (BENTOMAT CLT, BENTOMAT CL, or BENTOMAT 600 CL).

4.2 When the GCL is placed over an earthen subgrade, the subgrade surface must be prepared in accordance with the project specifications. The engineer’s approval of the subgrade must be obtained prior to installation. The finished surface should be firm and unyielding, without abrupt elevation changes, voids, cracks, ice, or standing water.

- 6 -

I N S TA L L AT I O N G U I D E L I N E S

GEOSYNTHETIC CLAY LINERS

2870 Forbs Avenue Hoffman Estates, IL 60192

847.851.1800 | 800.527.9948

4.3 The subgrade surface must be smooth and free of vegetation, sharp-edged rocks, stones, sticks, construction debris, and other foreign matter that could contact the GCL. The subgrade should be rolled with a smooth-drum compactor to remove any wheel ruts greater than 1 inch in depth, footprints, or other abrupt grade changes. Furthermore, all protrusions extending more than 0.5 inch (12 mm) from the subgrade surface shall be removed, crushed, or pushed into the surface with a smooth-drum compactor. The GCL may be installed on a frozen subgrade, but the subgrade soil in the unfrozen state should meet the above requirements.

SECTION 5

INSTALLATION

5.1 GCL rolls should be taken to the work area of the site in their original packaging. The orientation of the GCL (i.e., which side faces up) may be important if the GCL has two different types of geosynthetics. Check with the project engineer to determine if there is a preferred installation orientation for the GCL. If no specific orientation is required, allow the roll to unwind from the bottom rather than pulling from the top (Figure 5A). The arrow sticker on the plastic sleeve indicates the direction that the GCL will naturally unroll when placed on the ground (Figure 6). Prior to deployment, the packaging should be carefully removed without damaging the GCL.

5.2 Equipment which could damage the GCL should not be allowed to travel directly on it. Therefore, acceptable installation may be accomplished whereby the GCL is unrolled in front of backwards-moving equipment (Figure 7). If the installation equipment causes rutting of the subgrade, the subgrade must be restored to its originally accepted condition before placement continues.

5.3 If sufficient access is available, GCL may be deployed by suspending the roll at the top of the slope, with a group of laborers pulling the material off of the roll, and down the slope (Figure 8).

5.4 GCL rolls should not be released on the slope and allowed to unroll freely by gravity.

FIGURE 5 A & B

“NATURAL’ ORIENTATION (5A)

TOP OF THE ROLL (5B)

FIGURE 6 - DIRECTION TO UNROLL GCL ON GROUND PER FIGURE 5A

FIGURE 8 - UNROLLING BENTOMAT

5.5 Care must be taken to minimize the extent to which the GCL is dragged across the subgrade to avoid damage to the bottom surface of the GCL. Care must also be taken when adjusting BENTOMAT CLT panels to avoid damage to the geotextile surface of one panel of GCL by the textured sheet of another panel of GCL. A temporary geosynthetic subgrade cover commonly known as a slip sheet or rub sheet may be used to reduce friction damage during placement.

5.6 The GCL should be placed so that seams are parallel to the direction of the slope. End-of-panel seams should also be located at least 3 ft (1 m) from the toe and crest of slopes steeper than 4H:1V. End-of-roll seams on slopes should be used only if the liner is not expected to be in tension.

5.7 All GCL panels should lie flat, with no wrinkles or folds, especially at the exposed edges of the panels. When BENTOMAT geosynthetic clay liners with SUPERGROOVE® is repositioned, it should be gripped inside the SUPERGROOVE by folding the edge.

5.8 The GCL should not be installed in standing water or during rainy weather. Only as much GCL shall be deployed as can be covered at the end of the working day with soil, geomembrane, or a temporary waterproof tarpaulin. The GCL shall not be left uncovered overnight. If the GCL is hydrated when no confining stress is present, it may be necessary to remove and replace the hydrated material. CETCO recommends that premature hydration be evaluated on a case-by-case basis. The project engineer, CQA inspector, and CETCO TR-312 should be consulted for specific guidance if premature hydration occurs. The type of GCL, duration of exposure, degree of hydration, location in the liner system, and expected bearing loads should all be considered.

FIGURE 7 - TYPICAL BENTOMAT® INSTALLATION TECHNIQUE

- 8 -

I N S TA L L AT I O N G U I D E L I N E S

GEOSYNTHETIC CLAY LINERS

2870 Forbs Avenue Hoffman Estates, IL 60192

847.851.1800 | 800.527.9948

In many instances, a needlepunch reinforced GCL may not require removal/replacement if the following are true:

5.9 For the convenience of the installer, hash marks are placed on BENTOMAT goesynthetic clay liners every 5’ (1.5 m) of length.

SECTION 6

ANCHORAGE

6.1 If required by the project drawings, the end of the GCL roll should be placed in an anchor trench at the top of a slope. The front edge of the trench should be rounded to eliminate any sharp corners that could cause excessive stress on the GCL. Loose soil should be removed or compacted into the floor of the trench.

FIGURE 9 - TYPICAL ANCHOR TRENCH DESIGN

Rounded Corner

GCL

Varies

Compacted Soil Back�ll

18" (450 mm)

Compacted Subgrade24

0 m m

6.2 If a trench is used for anchoring the end of the GCL, soil backfill should be placed in the trench to provide resistance against pullout. The size and shape of the trench, as well as the appropriate backfill procedures should be in accordance with the project drawings and specifications. Typical dimensions are shown in Figure 9.

6.3 The GCL should be placed in the anchor trench such that it covers the entire trench floor but does not extend up the rear trench wall.

6.4 Sufficient anchorage may alternately be obtained by extending the end of the GCL roll back from the crest of the slope, and placing cover soil. The length of this “runout” anchor should be prepared in accordance with project drawings and specifications.

SECTION 7

SEAMING

7.1 GCL seams are constructed by overlapping adjacent panel edges and ends. Care should be taken to ensure that the overlap zone is not contaminated with loose soil or other debris. BENTOMAT 200R, BENTOMAT ST, BENTOMAT DN, and BENTOMAT SDN have SUPERGROOVE® which provides self-seaming capabilities in their longitudinal overlaps, and therefore do not require supplemental bentonite. However, for pond applications, supplemental bentonite must be used in longitudinal seams, regardless of the

CETCO GCL.

FIGURE 10 - SUPERGROOVE®

7.2 Longitudinal seams should be overlapped a minimum of 6 inches (150 mm) for BENTOMAT geosynthetic clay liners. For high-head applications (greater than 1 foot or 20.48 cm) involving BENTOMAT CL, BENTOMAT CLT, or BENTOMAT 600 CL, a minimum longitudinal seam overlap of 12 inches (300 mm) and supplemental bentonite (per Section 7.6) is recommended.

7.3 End-of-panel overlapped seams should be overlapped 24 inches (600 mm) for BENTOMAT geosynthetic clay liners.

7.4 End-of-panel overlapped seams are constructed such that they are shingled in the direction of the grade to prevent runoff from entering the overlap zone. End-of-panel seams on slopes are permissible, provided adequate slope stability analysis has been conducted (i.e., the GCL is not expected to be in tension).

Bentonite-enhanced seams are required for all BENTOMAT end-of-panel overlapped seams.

7.5 BENTOMAT end-of-panel, bentonite-enhanced, overlapped seams are constructed first by overlapping the adjacent panels, exposing the underlying panel, and then applying a continuous bead or fillet of granular sodium bentonite 12” from the edge of the underlying panel (Figure 11). The minimum application rate at which the bentonite is applied is one-quarter pound per linear foot (0.4 kg/m).

7.6 If longitudinal bentonite enhanced seams are required for BENTOMAT 200R, BENTOMAT ST, BENTOMAT DN, or BENTOMAT SDN, they are constructed by overlapping the adjacent panels a minimum 6 inches (150 mm), exposing the underlying edge, and applying a continuous bead of granular bentonite approximately 3 inches (75 mm) from the edge. For pond applications involving BENTOMAT CL or BENTOMAT CLT, longitudinal seams are constructed by overlapping adjacent panels by 12 inches (300 mm), exposing the underlying edge, and applying a continuous bead of bentonite approximately 6 inches (150 mm) from the edge. The minimum application rate for the granular bentonite is one quarter pound per linear foot (0.4 kg/m).

FIGURE 11

BENTOMAT END-OF-PANEL OVERLAPPED SEAM

SECTION 8

SEALING AROUND PENETRATIONS

AND STRUCTURES

8.1 Cutting the GCL should be performed using a sharp utility knife.

Frequent blade changes are recommended to avoid irregular tearing of the geotextile components of the GCL during the cutting process.

8.2 The GCL should be sealed around penetrations and structures embedded in the subgrade in accordance with Figures 12 through 14. Granular bentonite shall be used liberally (approximately 0.25 lbs/ln. ft. or 0.4 kg/m) to seal the GCL to these structures.

- 10 -

I N S TA L L AT I O N G U I D E L I N E S

GEOSYNTHETIC CLAY LINERS

2870 Forbs Avenue Hoffman Estates, IL 60192

847.851.1800 | 800.527.9948

FIGURE 12 A CROSS-SECTION OF A HORIZONTAL PIPE PENETRATION

FIGURE 12 B ISOMETRIC VIEW OF A COMPLETED HORIZONTAL PIPE PENETRATION

FIGURE 13 A CROSS-SECTION OF A VERTICAL PENETRATION

Granular Bentonite Primary GCL Layer

Subgrade Secondary GCL Collar

1 ft. (300 mm. min. overlap)

Primary GCL Layer Secondary GCL Collar

Vertical Penetration

Granular Bentonite 3" (75 mm) Typical

4" (100 mm) Typical

FIGURE 13B ISOMETRIC VIEW OF THE COMPLETED VERTICAL PENETRATION

FIGURE 14 CROSS-SECTION OF GCL SEAL AGAINST AN EMBEDDED STRUCTURE OR WALL

Soil or Gravel

Prepared Subgrade

Granular Bentonite GCL

0 m m

4" (100 mm)

Wall or

Foundation

6" (150 mm)

3" (75 mm)

- 12 -

I N S TA L L AT I O N G U I D E L I N E S

GEOSYNTHETIC CLAY LINERS

2870 Forbs Avenue Hoffman Estates, IL 60192

847.851.1800 | 800.527.9948

8.3 When the GCL is placed over a horizontal pipe penetration, a “notch” should be excavated into the subgrade around the penetration (Figure 12a). The notch should then be backfilled with granular bentonite. A secondary collar of GCL should be placed around the penetration, as shown in Figure 12b. It is helpful to first trace an outline of the penetration on the GCL and then cut a “star” pattern in the collar to enhance the collar’s fit to the penetration. Granular bentonite should be applied between the primary GCL layer and the secondary GCL collar.

8.4 Vertical penetrations are prepared by notching into the subgrade as shown in Figure 13a. The penetration can be completed with two separate pieces of GCL as shown in Figure 13b. Alternatively, a secondary collar can be placed as shown in Figure 12a or 12b.

8.5 When the GCL is terminated at a structure or wall that is embedded into the subgrade on the floor of the containment area, the subgrade should be notched, as described in Sections

8.3 and 8.4. The notch is filled with granular bentonite; the GCL should be placed over the notch and up against the structure (Figure 14). Connection to the structure can be accomplished by placement of soil or stone backfill in this area. When structures or walls are at the top of a slope, additional detailing may be required. Contact CETCO for specific guidance.

SECTION 9

DAMAGE REPAIR

9.1 If the GCL is damaged (torn, punctured, perforated, etc.) during installation, it may be possible to repair it by cutting a patch to fit over the damaged area (Figure 15). The patch should be cut to size such that a minimum overlap of 12 inches (300 mm) is achieved around all parts of the damaged area. Granular bentonite should be applied around the damaged area prior to placement of the patch. It may be necessary to use an adhesive such as wood glue to affix the patch in place so that it is not displaced during cover placement. Smaller patches may be tucked under the damaged area to prevent patch movement.

FIGURE 15 DAMAGE REPAIR BY PATCHING

SECTION 10

COVER PLACEMENT

10.1 The final thickness of soil cover on the GCL varies with the application. A minimum cover layer must be at least 1 foot (300 mm) thick to provide confining stress to the GCL, eliminate the potential for seam separation and prevent damage by equipment, erosion, etc.

10.2 Cover soils should be free of angular stones or other foreign matter that could damage the GCL. Cover soils should be approved by the engineer with respect to particle size, uniformity, and chemical compatibility. Consult CETCO if cover soils have high concentrations of calcium (e.g. limestone, dolomite, gypsum, seashell fragments).

10.3 Recommended cover soils should have a particle size distribution ranging between fines and 1 inch (25 mm), unless a cushioning geotextile is specified.

10.4 Soil cover shall be placed over the GCL using construction equipment that minimizes stresses on the GCL. A minimum thickness of 1 foot (300 mm) of cover soil should be maintained between the equipment tires/tracks and the GCL at all times during the covering process. In high-traffic areas such as on roadways, a minimum thickness of 2 feet (600 mm) is required.

10.5 Soil cover should be placed in a manner that prevents the soil from entering the GCL overlap zones. Soil cover should be pushed up on slopes, not down slopes, to minimize tensile forces on the GCL.

10.6 When a textured geomembrane is installed over the GCL, a temporary geosynthetic covering known as a slip sheet or rub sheet should be used to minimize friction during placement and to allow the textured geomembranes to be more easily moved into its final position.

10.7 Cyclical wetting and drying of GCL covered only with geomembrane can cause overlap separation. Soil cover should be placed promptly whenever possible. Geomembranes should be covered with a white geotextile and/or operations layer without delay to minimize the intensity of wet-dry cycling. If there is the potential for unconfined cyclic wetting and drying over an extended period of time, the longitudinal seam overlaps should be increased based on the project engineer’s recommendation.

10.8 To avoid seam separation, the GCL should not be put in excessive tension by the weight or movement of textured geomembrane on steep slopes. If there is the potential for unconfined geomembrane expansion and contraction over an extended period of time, the longitudinal seam overlaps should be increased based upon the project engineer’s recommendation.

SECTION 11

HYDRATION

11.1 Hydration is usually accomplished by natural rainfall and/ or absorption of moisture from soil. However, in cases where the containment of non-aqueous liquid is required, it may be necessary to hydrate the covered GCL with water prior to use.

11.2 If manual hydration is necessary, water can be introduced by flooding the covered lined area or using a sprinkler system. If flooding, care must be taken to diffuse the energy of the water discharge so that the cover material is not displaced.

11.3 If the GCL is hydrated when no confining stress is present, it may be necessary to remove and replace the hydrated material.

As discussed in Section 5.8, in many instances a needlepunch reinforced GCL may not require removal/replacement if the following are true:

- 14 -

N O T E S

GEOSYNTHETIC CLAY LINERS

2870 Forbs Avenue Hoffman Estates, IL 60192

847.851.1800 | 800.527.9948

CETCO, a wholly owned subsidiary of AMCOL International Corp.

2870 Forbs Avenue, Hoffman Estates, IL 60192

847.851.1800 | 800.527.9948 | cetco.com amcol.com

AMCOL® INTERNATIONAL HEADQUARTERS

Headquartered in Hoffman Estates, IL, AMCOL International

Corporation (AMCOL) operates over 68 facilities in Africa, Asia, Australia, Europe, North America and South America. AMCOL employs more than 1,750 employees in 26 countries. The company, established in 1927, currently trades on the New York

Stock Exchange under the symbol “ACO”. AMCOL produces and markets a wide range of specialty mineral products used for industrial, environmental and consumer-related applications.

With more than 68 world-wide locations, AMCOL manages a global supply chain to deliver world-class quality. Our full range of products and services allow us to bring value to our customers, but ultimately, our commitment to understanding customer’s needs is what sets us apart in our industry.

IMPORTANT: The information contained herein is believed to be accurate and reliable.

This document supersedes all previous printed versions. For the most up-to-date information, please visit www.CETCO.com. CETCO accepts no responsibility for the results obtained throughout application of this product. CETCO reserves the right to update information without notice.

© 2010 CETCO | PRINTED IN THE USA ON RECYCLED PAPER

DECEMBER 2010

TR-403

Revised 11/09

800.527.9948 Fax 847.851.1899

For the most up-to-date product information, please visit our website, www.cetco.com.

A wholly owned subsidiary of AMCOL International Corporation. The information and data contained herein are believed to be accurate and reliable, CETCO makes no warranty of any kind and accepts no responsibility for the results obtained through application of this information.

CETCO GCL

MANUFACTURING QUALITY ASSURANCE

AND QUALITY CONTROL (MQC) MANUAL

Version 8.0, November 2009

CONFIDENTIALITY NOTICE

This manual contains confidential company information and is to be distributed exclusively to those personnel who are directly involved with the manufacturing and evaluation of Bentomat. THIS

DOCUMENT SHALL NOT BE PUBLICLY DISTRIBUTED WITHOUT THE EXPRESS CONSENT

(VERBAL OR WRITTEN) OF COLLOID ENVIRONMENTAL TECHNOLOGIES COMPANY.

800.527.9948 Fax 847.851.1899

For the most up-to-date product information, please visit our website, www.cetco.com.

A wholly owned subsidiary of AMCOL International Corporation. The information and data contained herein are believed to be accurate and reliable, CETCO makes no warranty of any kind and accepts no responsibility for the results obtained through application of this information.

POLICY STATEMENT

The Geosynthetic Clay Liner (GCL) Manufacturing Quality Assurance/Quality Control Manual has been prepared by Colloid Environmental Technologies Company (CETCO), a wholly owned subsidiary of AMCOL International, Inc. This policy states that our primary goal is to achieve optimum productivity while assuring full customer satisfaction. To reach this goal, CETCO is committed to the pursuit of continuous improvement of all processes and materials utilized in the manufacture of GCL.

800.527.9948 Fax 847.851.1899

For the most up-to-date product information, please visit our website, www.cetco.com.

A wholly owned subsidiary of AMCOL International Corporation. The information and data contained herein are believed to be accurate and reliable, CETCO makes no warranty of any kind and accepts no responsibility for the results obtained through application of this information.

TABLE OF CONTENTS

Section Page

1 INTRODUCTION 5

1.1 Definitions 5

1.2 MQA/MQC Objectives 5

1.3 Revisions 6

1.4 Audits 6

2 MQA/MQC PROCEDURES 7

2.1 Geosynthetic Components 7

2.1.1 Woven Geotextile 7

2.1.2 Non-Woven Geotextile 7

2.1.3 Geomembrane/Geofilm Laminated to Geosynthetic 8

2.2 Sodium Bentonite 8

2.3 Production Processes 8

2.3.1 Punch Density 9

2.3.2 Lamination (CL Series) 9

2.3.3 Roll Length and Width 9

2.3.4 External Markings 9

2.3.5 Equipment Inspection 9

2.4 Finished GCL 10

2.5 Needle Detection and Removal 11

2.6 Plant Storage and Handling 11

3 RECORD KEEPING AND REPORTING 12

3.1 Plant Records 12

3.2 CETCO Laboratory Records 13

3.3 GCL Manufacturing Certification Reports 13

4 SUMMARY OF GCL MQA/MQC PLAN 15

800.527.9948 Fax 847.851.1899

For the most up-to-date product information, please visit our website, www.cetco.com.

A wholly owned subsidiary of AMCOL International Corporation. The information and data contained herein are believed to be accurate and reliable, CETCO makes no warranty of any kind and accepts no responsibility for the results obtained through application of this information.

LIST OF FIGURES

Figure Page

1-1 CETCO GCL MQA/MQC Program Organization Chart 16

1-2 Contract Review 17

2-1 Guide for Obtaining Samples and Test Specimens 18

2-2 Schematic of Needle Detection and Removal System 19

LIST OF TABLES

Table Page

2-1 MQA Parameters for Geotextile Component of GCL 21

2-2 MQC Parameters for FML/Geosynthetic Component of Claymax 22

2-3 MQA Parameters for Bentonite Component of GCL 23

2-4 MQA/MQC Parameters for Finished GCL 24

4-1 Bentomat MQA/MQC Plan Summary 25

4-2 Claymax MQA/MQC Plan Summary 27

LIST OF APPENDICES

Appendix

A Referenced Standards and Test Methods 28

B Sample CETCO GCL MQA/MQC Report

800.527.9948 Fax 847.851.1899

For the most up-to-date product information, please visit our website, www.cetco.com.

A wholly owned subsidiary of AMCOL International Corporation. The information and data contained herein are believed to be accurate and reliable, CETCO makes no warranty of any kind and accepts no responsibility for the results obtained through application of this information.

SECTION 1

INTRODUCTION

1.1 Definitions

This manual contains objectives and criteria for maintaining CETCO Geosynthetic Clay Liner (GCL) Manufacturing Quality Control and Manufacturing Quality Assurance as defined below:

Manufacturing Quality Control (MQC) refers to a planned system of inspections for directly monitoring and controlling the quality of the GCL product during the manufacturing process. MQC is performed by CETCO to ensure that the specified values for GCLs are achieved.

Manufacturing Quality Assurance (MQA) refers to a planned system of activities that provide assurance that the manufactured GCLs product actually meets its specified properties.

The above definitions, provided by Koerner and Daniel1, imply that MQC procedures are implemented to control the product during manufacture, while MQA procedures are implemented to ensure the product meets specifications after manufacture. CETCO GCLs are assembled from three component materials, meaning that there are four materials streams (two geosynthetics, the clay, and the finished product) which are subject to either MQA or MQC. Quality control procedures are implemented on those components and finished products which are manufactured by CETCO. Quality assurance procedures are implemented on the components of GCL that are furnished by outside suppliers.

Therefore, this manual contains an integrated series of procedures that may be classified as both MQA and MQC, as determined by the source of the component materials.

The organizational structure of the CETCO GCL MQA/MQC Program is depicted in Figure 1-1. The "core" quality personnel are shown in the center of the diagram, with peripheral quality support provided by the other personnel. For each project, the CETCO GCL Sales Manager is the key liaison between the manufacturer and the engineer, and any special MQA/MQC issues which deviate from this manual should be communicated between these two parties prior to production for the project.

Figure 1-2 presents the Order Review Process for discrepancies between contract specifications and CETCO standard GCL specifications.

1.2 MQA/MQC Objectives

CETCO GCLs are utilized in a wide variety of important environmental and engineering applications which often provide protection of human health and the environment from contaminated soil or water.

Accordingly, CETCO GCLs have been designed with certain engineering properties which make it suitable for use in these critical applications. The quality of CETCO GCLs has a direct influence on the degree of environmental protection they provide. It is therefore of paramount importance that the entire manufacturing process for CETCO GCLs is tightly controlled and monitored through the implementation of a comprehensive quality management system.

1 Koerner, R.M. and D.E. Daniel (1992) Manufacturing and Construction Quality Control and Quality Assurance of Geosynthetics.

Proceedings of the 6th GRI Seminar: MQC/MQA and CQC/CQA of Geosynthetics, December 10-11, 1992, Philadelphia, PA, pp. 1-14.

800.527.9948 Fax 847.851.1899

For the most up-to-date product information, please visit our website, www.cetco.com.

A wholly owned subsidiary of AMCOL International Corporation. The information and data contained herein are believed to be accurate and reliable, CETCO makes no warranty of any kind and accepts no responsibility for the results obtained through application of this information.

CETCO is registered with the International Organization for Standardization (ISO) and follows a quality management system in accordance with ISO 9001:2000. The intent of the quality management system is to ensure that we provide products and services that conform to the requirements of our customers and to deliver them on time and without defects. The Quality Manual and associated quality procedures, work instructions, calibration procedures, test procedures, and records, are saved electronically. The procedures outlined in this MQA/MQC manual are also described in the ISO Quality Manual.

This MQA/MQC manual establishes the manufacturing guidelines and product testing procedures necessary to ensure that CETCO GCLs meet all of their design specifications. Where applicable, established ASTM sampling and testing methodologies and protocols for GCLs or its components are specified for use.

The remainder of this manual is presented in three sections. Section 2 contains test procedures for GCLs and each of its components, and Section 3 describes the record keeping and reporting procedures which will document adherence to this plan and will verify the overall quality of the product. Lastly, Section 4 presents in tabular form an overall summary of the manufacturing QA/QC program.

1.3 Revisions

Because one of CETCO's corporate commitments is continual product improvement, the procedures specified in this manual may require some modifications as such improvements occur. Interim revisions to the existing manual will be issued as required, and the manual itself will be updated and reissued on a regular basis to incorporate recent revisions. It is every employee's responsibility to remain abreast of the continued revisions to the quality program.

1.4 Audits

Formal internal audits of the GCL manufacturing quality program will be conducted annually by CETCO and by a third-party ISO auditor in order to determine the adequacy of quality procedures and the degree of conformance with these procedures. Informal audits will be conducted on an as-needed basis by plant management.

Results of the audits will be distributed to the CETCO Management Representative, to the Plant Manager, and to corporate management. If the audit reveals that major corrective actions are required to achieve conformance with quality objectives, a quality improvement plan will be prepared and submitted to the CETCO Management Representative. A file of all audits and corrective action plans will be maintained by CETCO. Implementation of the quality improvement plan will be managed by the CETCO Management Representative and/or Plant Manager.

800.527.9948 Fax 847.851.1899

For the most up-to-date product information, please visit our website, www.cetco.com.

A wholly owned subsidiary of AMCOL International Corporation. The information and data contained herein are believed to be accurate and reliable, CETCO makes no warranty of any kind and accepts no responsibility for the results obtained through application of this information.

SECTION 2

MQA/MQC PROCEDURES

This section of the CETCO GCL Manufacturing QA/QC Manual describes specific procedures carried out to evaluate the quality of each GCL component (top geosynthetic, bottom geosynthetic, bentonite clay), the quality of the actual production process, and the quality of the finished GCL product. This program allows immediate verification of critical production parameters used to monitor production quality, while the laboratory test program will verify the specified engineering characteristics of the

GCL.

2.1 Geosynthetic Components

Depending upon the type of GCL the top and bottom geosynthetic components may consist either of a woven geotextile, nonwoven geotextile, or flexible membrane liner laminated to a geotextile. ASTM D5889 states the minimum types of tests and their frequencies for the MQC of the geosynthetic materials used in the GCL.

2.1.1 Woven Geotextile

The woven geotextile is manufactured elsewhere and is delivered to the GCL plant in rolls up to 1,500 yards long, depending on the style being used. CETCO receives and maintains on file manufacturer's certifications stating that the products meet the engineering specifications listed in Table 2-1.

Each geotextile roll is labeled with a lot and roll number, and the date and time at which a roll is placed into GCL production is recorded on a daily operating log. This procedure allows the usage of the woven geotextile to be tracked such that its lot and roll number can be directly determined from the corresponding GCL lot and roll number.

If the overall quality of the of the woven geotextile roll is unknown (e.g., not certified by the manufacturer, lot and roll tag missing, or the data misplaced) full roll-width samples are obtained at a frequency of one per every 200,000 square feet to confirm that the geotextile is acceptable with respect to its required mass per unit area and grab strength values.

2.1.2 Non-Woven Geotextile

The non-woven needlepunched geotextile is manufactured in rolls up to 1,500 yards long by CETCO or elsewhere and is subjected to conformance tests at the plant of origin prior to delivery to the GCL plant. CETCO receives and maintains on file manufacturer's certifications stating that the products meet the engineering specifications listed in Table 2-1.

Each geotextile roll is labeled with a lot and roll number, and the date and time at which a roll is placed into GCL production is recorded on a daily operating log. This procedure allows the usage of the woven geotextile to be tracked such that its lot and roll number can be directly determined from the corresponding GCL lot and roll number.

800.527.9948 Fax 847.851.1899

For the most up-to-date product information, please visit our website, www.cetco.com.

A wholly owned subsidiary of AMCOL International Corporation. The information and data contained herein are believed to be accurate and reliable, CETCO makes no warranty of any kind and accepts no responsibility for the results obtained through application of this information.

If the overall quality of the of the woven geotextile roll is unknown (e.g., not certified by the manufacturer, lot and roll tag missing, or the data misplaced) full roll-width samples are obtained at a frequency of one per every 200,000 square feet to confirm that the geotextile is acceptable with respect to its required mass per unit area and grab strength values.

2.1.3 Geomembrane/Geofilm Laminated to Geosynthetic

When a geomembrane or geofilm is laminated to the GCL as in the CL Product Series, the geomembrane or geofilm shall be subjected to the MQC testing outlined in Table 2-2 either by the supplier or by CETCO.

2.2 Sodium Bentonite

ASTM D5889 identifies the minimum types of tests and their frequencies for the MQC of sodium bentonite prior to incorporation into GCLs. Granular sodium bentonite incorporated into the GCL is supplied by one or more bentonite plants. The bentonite manufacturer provides test data for each shipment received at the GCL plant.

The sodium bentonite is typically railed or conveyed to the GCL plants. Railcars hold approximately 90 tons. The clay testing is therefore performed twice per railcar, but a minimum of every 50 tons. QA procedures for bentonite shipped to the GCL plant primarily involves collecting and maintaining Certificates of Analysis (COAs) issued by the bentonite manufacturer with each bentonite shipment.

The quality parameters for the sodium bentonite are its swell index and fluid loss, which are indicators of GCL hydraulic performance. The clay in CETCO GCLs has a minimum swell index of 24 mL/2g, as determined in accordance with ASTM D5890. The clay in CETCO GCLs has a maximum fluid loss value of 18 mL, as determined in accordance with ASTM D5891. A summary of the bentonite MQA parameters is provided in Table 2-3.

Additionally, shipment COAs indicate moisture content and particle sizing. These properties do not pertain to final GCL quality. They pertain to properties needed for efficient processing of the bentonite into the GCL at CETCO plants. They are not part of the ASTM D5889 GCL Quality Control.

The CETCO bentonite COAs are received and retained at the GCL plant, and the accompanying clay lot numbers are recorded in the operations log using procedures similar to those described in Section

2.1 for the geosynthetic components. In order to coordinate the usage of the certified bentonite and the production of GCL, the lot number and the time/date of use is recorded in the daily log. Thus, the daily log allows every roll of GCL to be traced to the bentonite lot number. More information regarding the reporting and record keeping procedures is presented in Section 3.

2.3 Production Processes

The machinery utilized for the production of GCLs is highly controlled, and critical production parameters are automatically monitored. Human input into the manufacturing process is critical, however, to the extent necessary to maintain the machinery and the requisite QA/QC information. As described below, quality control procedures during production focus primarily on maintaining the calibration and operation of the production system.

800.527.9948 Fax 847.851.1899

For the most up-to-date product information, please visit our website, www.cetco.com.

A wholly owned subsidiary of AMCOL International Corporation. The information and data contained herein are believed to be accurate and reliable, CETCO makes no warranty of any kind and accepts no responsibility for the results obtained through application of this information.

2.3.1 Punch Density (Bentomat GCLs Only)

Punch density refers to the number of needlepunched fibers per unit area joining the top and bottom geotextiles of the Bentomat GCLs.