CMAR_for_Concrete_Pressure_Pipe_CFRP_Rehabilitation_(Addendum_#1_Revision).pdf

CITY OF TUCSON

REQUEST FOR QUALIFICATIONS

260113

CMAR FOR CONCRETE PRESSURE PIPE CFRP REHABILITATION

Due Date: Wednesday, October 22, 2025

City of Tucson

255 W Alameda St

Tucson, AZ 85701

Procurement portal https://secure.procurenow.com/portal/tucson-az

Public Portal https://secure.procurenow.com/portal/tucson-az/projects/34718

PUBLISH DATE: September 17, 2025 https://secure.procurenow.com/portal/%7Bproject.government.code%7D https://secure.procurenow.com/portal/%7Bproject.government.code%7D/projects/%7Bproject.id%7D https://secure.procurenow.com/portal/%7Bproject.government.code%7D/projects/%7Bproject.id%7D

CITY OF TUCSON REQUEST FOR QUALIFICATIONS NO. 260113

BUSINESS SERVICES DEPARTMENT Page 2 of 104 SHARED SERVICES PROCUREMENT DIVISION RESPONSIBLE CONTRACT OFFICER: Vanessa Guzman

255 W. ALAMEDA, 6TH FLOOR, TUCSON, AZ 85701 PH: (520) 837-4375

Attachments:

A - OFFER AND ACCEPTANCE.RFQ

B - SBE Provisions

BUSINESS SERVICES DEPARTMENT Page 3 of 104

A. Notice

A.1. CITY OF TUCSON

NOTICE OF REQUEST FOR QUALIFICATIONS NO 260113

CMAR for Concrete Pressure Pipe CFRP Rehabilitation

Pursuant to ARS Title 34, the City of Tucson is conducting a competitive One-Step Process to select a qualified construction manager/general contractor to provide design phase assistance for complete construction service as the Construction Manager at Risk for construction improvements for CMAR for Concrete Pressure Pipe CFRP Rehabilitation. The estimated construction cost for projects could exceed fifty million dollars ($50,000,000).

The City invites interested firms to submit written Statements of Qualifications (SOQ’s) relating to this solicitation. A Screening Committee will evaluate firms’ qualifications and experience with similar projects. The top ranked firm(s) will then be invited to enter into negotiations with the City of Tucson.

SUBMITTAL DUE DATE: Wednesday, October 22, 2025 AT 2:00 pm LOCAL AZ TIME

PRE-SUBMITTAL CONFERENCE DATE: Wednesday, October 1, 2025

TIME: 10:00 am LOCAL AZ TIME

LOCATION: Microsoft Teams

CLICK HERE TO JOIN THE MEETING

Meeting ID: 228 934 946 464 1 Passcode: bi69Nx7N

Or Dial in by Phone +1 213-293-2303,,579065975# United States, Los Angeles Find a local number Phone conference ID: 579 065 975#

QUESTIONS SHALL BE DIRECTED TO: Vanessa Guzman

(520) 837-4375 vanessa.guzman@tucsonaz.gov

Publication Dates: Thursday, September 18, 2025 and Thursday, September 25, 2025

Posted Date: Wednesday, September 17, 2025 https://teams.microsoft.com/l/meetup-join/19%3ameeting_NWQ1MDJkZDYtZTc3MS00MTY2LWI5NWMtYTk0ZjBiYWFjY2Jl%40thread.v2/0?context=%7b%22Tid%22%3a%22d21e59ec-c208-43eb-aaf1-cf06d9a196e0%22%2c%22Oid%22%3a%22de1302c3-4c28-4ff5-92ab-edd57dfd8a44%22%7d tel:+12132932303,,579065975 https://dialin.teams.microsoft.com/2c60b41f-ade1-4bcb-8fa6-36d6e327015e?id=579065975

BUSINESS SERVICES DEPARTMENT Page 4 of 104

B. Introduction

B.1. Summary

The City of Tucson, (COT), is conducting a competitive process to retain a Contractor to perform internal pipe renewals on Tucson Water’s most critical water transmission mains consisting of concrete pressure pipe. Services will be used to perform Carbon Fiber Reinforced Polymer (CFRP) pipe renewal.

The City may, at its sole discretion, award multiple projects under the resulting contract, or go out for competitive bids, or go out for another CMAR.

B.2. Background

Tucson Water has previously used the JOC contract to perform the internal pipeline lining or pipe renewal. Typically, each project did not exceed 1 million dollars. However, at the time, an alternative analysis was performed and their was determined that CFRP was the best strategy to maintain the pipes structural integrity. Due to the budget difference, this contract vehicle is the best option.

CMAR Contracting is an alternative delivery method for construction of public works projects. Which can be awarded on the basis of qualifications. Best value may be considered in awarding the JOC or in awarding job orders under the JOC contract.

During the term of the contract, work is performed by way of design. The design consultant and CMAR, in collaboration with the City, will be responsible to define, monitor and stay within the project budget and schedule. The CMAR firm will take an active role during the pre-construction services and serve as the General Contractor for the construction of the project. The CMAR, design engineer and City will manage the risk during preconstruction in such a way as to retire known risks when possible, develop a mitigation strategy for known risks that cannot be fully retired, include allowances in the Guaranteed Maximum Price (GMP) for known risks that cannot be retired, and include contingencies in the GMP for unknown or poorly defined risks. Scope, schedule, price, and liquidated damages (if applicable) are agreed upon in an executed Notice to Proceed letter prior to commencement of the work.

GMP means the sum of the maximum cost of the Work; the CMAR’s construction fee; general conditions fee; taxes, bonds, insurance costs; and bid contingency as proposed and approved pursuant to the CMAR Standard Terms & Conditions attached. The approved GMP will be made part of the Construction Services Agreement by executing an amendment or additional amendments for phased construction. The City reserves the right to transition to a Lump Sum pricing structure during or after negotiations with the CMAR.

The CMAR will be responsible for construction means and methods, and will help facilitate the selection of pre-qualified subcontractors based on qualifications to perform the work. The CMAR may also decide for the firm to perform specific work packages.

A. Pre-construction Phase Services by the CMAR may include the following:

1. Management Plans

2. Value Analysis/Engineering

3. Design/Constructability Reviews

4. Cost Model/Budget

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5. Schedule Development

6. Estimating/Price/GMP

7. Ordering of Long Lead-Time Materials

B. Construction Phase Services by the CMAR may include the following:

1. Team management/coordination

2. Critical Path Scheduling

3. Meeting minutes during design and construction

4. Processing submittals

5. Cost controls/change order management

6. Installation of Carbon Fiber system

7. Field management

8. Safety/QC programs

9. Project close out/warranty period services

10. SPECIAL CONTRACTING CONSIDERATIONS:

Tucson Water’s most critical water transmission mains consist of concrete pressure pipe. Historically, these types of pipes have failed catastrophically with severe consequences. Tucson Water has one documented 96-inch PCCP pipeline failure with the sudden release of water that occurred in 1999.

Additionally, one failure occurred in 2012 which did not have the sudden release of water. An early alert system called the Acoustic Monitoring unit alerted City staff in time to halt water delivery and isolate the transmission main. The City of Tucson condemned ten homes and spent approximately 10 million dollars as an end result of the failure. Tucson Water’s goal is to prevent any further catastrophic failures and continue a proactive pipeline management program.

B.3. Contact Information

Vanessa Guzman Contract Officer Email: vanessa.guzman@tucsonaz.gov Phone: (520) 837-4375 Department:

Water Department mailto:vanessa.guzman@tucsonaz.gov tel:(520)837-4375

BUSINESS SERVICES DEPARTMENT Page 6 of 104

C. Scope of Work

C.1. GENERAL REQUIREMENTS

A. The Contractor shall perform all Work in accordance with this Specification and the repair drawings. In case of any discrepancies or conflicts between the requirements of this Specification and the repair drawings, contact the Owner to verify which requirements control.

B. Part 1 deals with general requirements. Submittal requirements are in Part 2, qualifications requirements are in Part 3, product requirements are in Part 4, and execution requirements are in Part 5 of this specification.

C. When used in this Specification, the following abbreviations and/or words shall have the following meanings:

1. AWS: American Welding Society.

2. Carbon Fiber Reinforced Polymer (CFRP): A proprietary composite system consisting of carbon and associated fiber reinforcements and polymer adhesives/resins and installation requirements. All components of the CFRP system, including primer, thickened epoxy, fiber reinforcement, impregnating resin, and topcoat resin, shall be compatible and provided by the same Supplier.

3. CCP: Bar-wrapped Concrete Cylinder Pipe manufactured in accordance with AWWA C303.

4. Contractor: The entity entering into an agreement with the Owner to furnish services as defined in this scope of services.

5. Contractor’s Inspector: The Contractor’s Inspector is an inspector who is a part of the Contractor’s QC team and is responsible for performing all inspections specified herein, identifying any nonconformities or defects encountered in the storage and handling of material, surface preparation, saturation of fabric, installation, and curing, and ensuring application of corrective actions specified by the Engineer of Record (EOR) and approved by the Owner.

6. Engineer of Record (EOR): The Engineer of Record is the licensed professional engineer that: performs the design; prepares the repair drawings and specifications; reviews the submittals by the Manufacturer, Installer, and Contractor’s and Owner’s Inspectors, and makes recommendations to the Owner regarding their approval; provides technical support and reviews the Owner’s Inspector’s observations throughout the construction; reviews the results of tests on witness panels performed by a testing agency independent from the Installer and makes recommendations to the Owner regarding their approval; and prepares as-built drawings of the CFRP repair and a detailed report of all Work performed by Contractor.

7. Equipment: All goods, supplies, and apparatus to be furnished by the Contractor.

8. Glass Fiber Reinforced Polymer (GFRP): A composite lamina of unidirectional or woven glass fiber fabric reinforcement and resin used for insulating the carbon fiber from steel base to prevent galvanic corrosion or for watertightness. The CFRP layup with GFRP lamina used as a watertightness layer must have successfully passed the test required by

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AWWA C305 at twice the maximum design pressure.Installer: The contractor that installs the CFRP system on the concrete pressure pipe in accordance with all drawings and specifications issued by the EOR and performs all corrective actions specified by the EOR, the Owner, and Contractor’s and Owner’s Inspectors.

9. Manufacturer: The Manufacturer supplies all components of the CFRP system and provides all material data required in this scope of service / specification and instructions for delivery, storage, handling, and application of all materials.

10. Materials: All carbon fiber and other fiber reinforcements, polymer epoxy, primer, thickened epoxy, impregnating resin, and topcoat resin and hardware items related to CFRP system to be furnished under the Agreement. Materials are manufactured items that of themselves perform no specific function but that are intended as components of some apparatus, system, or engineered item.

11. Owner: The Owner is City of Tucson Water Department (Tucson Water). The Owner provides all data relevant to the design of the CFRP liner as requested by the EOR, such as pipeline properties, soil properties, design loads, and environmental conditions. The Owner also provides the EOR with all submittals by the Manufacturer, Installer, and Contractor’s and Owner’s Inspectors for review, and awards the Contract considering the results of this review.

12. Owner’s Inspector: The Owner’s Inspector is the EOR’s representative or an inspector that is independent from the Installer and Manufacturer. The Owner’s Inspector performs all inspections specified herein and reports to the EOR. The Owner’s Inspector monitors and documents all phases of the construction of the CFRP liner for compliance with all repair drawings and specifications and reports all non-conformances to the EOR for disposition and corrective action as necessary.

13. PCCP: Prestressed concrete cylinder pipe manufactured in accordance with AWWA C301.

14. Services: All labor to be furnished by the Contractor for design, installation, inspection and testing of the CFRP composite repairs.

15. Testing Agency: A qualified testing laboratory that is independent from the Installer and Manufacturer, capable of performing tests according to the ASTM standards specified herein. The Testing Agency is retained to perform tension tests on the CFRP witness panels and other materials prepared by the Installer during construction. The Testing Agency reports the test results to the EOR to review and make recommendations to the Owner for approval.

16. Work: All obligations undertaken by the Contractor to perform CFRP composite repairs on PCCP and CCP in the pipeline.

C.2. CONTRACTOR’S SCOPE OF WORK

The City, at its sole discretion, may award multiple projects to the selected Contractor including but not limited to:

o Columbus Blvd 54in Pipeline Renewal o Valencia Rd (Martin Reservoir to 22nd St. Reservoir)

BUSINESS SERVICES DEPARTMENT Page 8 of 104 o 48" C1-WSA o Other varying PCCP renewals, all monitored via AFO (48", 66", 78", 84", 96")

A. Work includes furnishing all materials, designs, equipment, services, training and supervision for installation, inspection and testing of CFRP composite repairs of concrete pressure pipe in accordance with the Drawings and this Specification, Owner’s site-specific requirements, and the contract issued by the Owner. The work covered under this contract, as described above and illustrated in the design plans provided, may be developed in multiple phases under one mobilization. The cost saving opportunities identified by the City and any value engineering opportunities brought forth by the selected CMAR firm shall protect the project goals and maintain the most valued components. The fundamental goals of the project include:

1. Long term renewal of large diameter concrete pressure pipe using CFRP system. Full extent of scope to be determined based on inspection results.

2. Implementation of CFRP installation with minimal impact on community and within schedule parameters established.

B. Provide the Installer that supplies the specified CFRP material and labor to install CFRP in concrete pressure pipe, including:

1. Preparing the internal concrete surface as required in the CFRP repair Drawings and this Specification.

2. Installing CFRP laminates in accordance with the CFRP repair Drawings and this Specification using the wet lay-up technique to the inside surface of the concrete pressure pipe. Access for all equipment, materials, and crew will be through existing manholes identified by the Owner.

3. Curing all installed CFRP in accordance with requirements in specification.

C. Contractor will mobilize and demobilize all required labor, equipment, and materials to and from the work site.

D. Contractor will provide all necessary equipment and personnel to complete Work in a timely manner and in accordance with applicable safety, engineering, and schedule requirements.

E. Safety requirements:

1. Contractor shall perform all phases of Work in accordance with the Owner’s site-specific safety requirements and the contract issued by the Owner.

2. Contractor’s Safety Manager shall communicate any safety violations to the Owner both verbally within the same shift and in writing.

F. Environmental:

1. Contractor shall perform all phases of Work in accordance with the Owner’s site-specific environmental requirements and the contract issued by the Owner.

2. Contractor shall communicate any environmental violations to the Owner both verbally within the same shift and in writing.

G. Contractor Project Management/Supervision:

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1. Contractor shall submit to the Owner resumes for key personnel that are going to be involved with the CFRP repair project (Design Integration Manager, Project Director, Project Manager, Field Superintendents, and Safety Manager). Key personnel changes must be approved by the Owner.

2. Contractor on-site PM/Superintendent must complete a documented daily report.

3. Contractor on-site management must have the authority to act on behalf of the Contractor.

4. Prepare and submit a project schedule for the CFRP repair.

H. Changes:

1. Any change to these requirements or any order may only be made by a change notice in accordance with the site-specific requirements and contract issued by the Owner.

I. Schedule:

1. Work shall be completed in accordance with the schedule approved by the Owner.

J. Construction Price:

1. Examples of areas with potential value engineering opportunities, which would satisfy the fundamental project goals, include are not limited to optimizing schedule and construction plan using available access points or suggestions for adding additional access points as needed.

2. Working with the design team and the City, the CMAR will assist in value engineering, constructability reviews, cost modeling, and other activities to be included in the pre-construction phase of the contract. The CMAR will immediately advise the City whenever the cost model indicates that the construction cost exceeds the construction budget for the project.

C.3. SUBMITTALS REQUIRED AT TIME OF GMP

All items listed in this paragraph shall be submitted with GMP.

A. By the Manufacturer:

1. Documents indicating conformance of the Manufacturer to the experience requirements in Paragraph 3.01B.

2. Product data sheets for all materials to be used in the CFRP and GFRP systems, including all material data specified in Paragraph 3.01D.

3. Watertightness test results as required in Paragraph 4.02D.

4. Safety Data Sheets for all materials to be used.

5. Documentation of previous satisfactory applications or thermal test results indicating satisfactory curing performance of the epoxy under the curing schedule recommended by the Manufacturer.

6. Letter from the Manufacturer indicating the allowable time windows between application of primer and thickened epoxy for each layer of the CFRP system, and between completion of

BUSINESS SERVICES DEPARTMENT Page 10 of 104 the CFRP layers and application of the topcoat considering the likely temperatures in the pipeline during construction.

7. Warranty as required in Paragraph 3.01E.

8. Delivery, storage, handling, and application instructions and general recommendations for each material to be used.

B. By the Installer:

1. Documents indicating conformance of the Installer to the experience requirements in Paragraph 3.02A.

2. Documents indicating training and compliance of the Installer with all site specific safety requirements.

3. Detailed Work schedule, step-by-step installation procedure, details of curing schedule, and equipment to be used.

4. Working drawings detailing the type, locations, dimensions, number of layers, and orientations of all CFRP materials to be installed.

5. Document indicating agreement of the Installer to have at least two field QC inspectors throughout the project execution as required by Paragraphs 3.02A.4 and 3.03.

C.4. SUBMITTALS REQUIRED AFTER AWARD OF CONTRACT PRIOR TO

CONSTRUCTION

A. By the Installer:

1. Documents indicating the details of the proposed quality control program.

2. Compliance of the field QC inspectors with the experience and training required.

3. Plan and details of proposed noise abatement measures, indicating compliance with site-specific requirements.

4. Developed risk register in collaboration with EOR and reviewed by the City.

5. Detailed construction schedule.

6. Detailed GMP breakout.

C.5. SUBMITTALS REQUIRED AFTER CONSTRUCTION

A. By the Installer for the EOR’s review and the Owner’s approval:

1. All quality control forms completed throughout the construction, including post-installation corrective actions, if any.

2. Marked-up repair drawings indicating as-built condition of the CFRP liners and end terminations installed.

B. By the Contractor’s Inspector for the EOR’s review and the Owner’s approval:

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1. Report of all inspections and tests performed on site with traceable records, notes, measurements, and photographs, and location and extent of post-installation repairs, if any.

C. By the Testing Agency for the EOR’s review and the Owner’s approval:

1. Results of all tension tests performed on witness panels with all required information listed in specification.

2. Results of all degree-of-cure tests performed on epoxy samples collected from the installed CFRP liners with all required information listed in specification.

C.6. QUALIFICATION OF CFRP SYSTEM MANUFACTURER

I. QUALIFICATIONS OF CFRP SYSTEM MANUFACTURER

The proposed CFRP system shall satisfy all testing requirements and exceed all acceptance criteria listed below. Material not complying with these requirements shall be rejected. All components of CFRP system submitted for approval shall have independent laboratory test reports indicating all details of testing. All components of the CFRP system shall be qualified prior to application.

A. Durability Testing:

1. The material shall meet environmental durability test requirements specified in AWWA Standard C305.

B. In-Service History of Material System:

1. The CFRP system Manufacturer shall provide:

a. Documented in-service history of over 10 years.

b. A minimum of 100 CFRP internal pipe rehabilitation projects.

c. The CFRP system shall have documented in-service history of over five years and a minimum of 50 PCCP segments of 30 in. diameter and above on five or more projects for internal repair and strengthening applications.

2. For a project to be considered applicable, it must involve the following: internal application of CFRP on pipelines greater than 30-inch diameter, with pressures greater than 50 psi operating pressure, where the same CFRP system proposed for use on this project has been used as a stand-alone upgrade of the pipeline without reliance on the host pipe for structural integrity. The minimum project length shall be 20 lineal feet of repair. A list of project references meeting these requirements shall be provided with Owner’s contact information for each project.

C. Minimum Required Properties for Material Qualification[PG1] [RO2] :

1. This section lists the minimum material qualification requirements for consideration for design of the CFRP liner. Satisfying these criteria does not guarantee that the repair layups specified on the design drawings would be applicable to the proposed material, because the designs shown on the drawings are based on the properties of specified CFRP products. See Paragraph 4.01G.

2. The mechanical properties of CFRP lamina, epoxy, and epoxy mortar shall be determined using ASTM standard test methods specified in Table 1. The characteristic values of these

BUSINESS SERVICES DEPARTMENT Page 12 of 104 mechanical properties, determined in accordance with ASTM D7290, shall be equal or greater than the minimum values listed in Table 1.

3. The test reports shall indicate clearly the commercial names of the products used, batch ID, sample dimensions, number of samples tested, number of fabric layers used, load and strain measurement techniques, failure modes, and obtained strength, modulus, ultimate elongation, and ultimate tensile force per inch width for each sample tested. Any deviation from the specified ASTM standards shall be clearly reported. Test reports shall indicate that the reported properties are based on the fiber-to-resin weight ratio recommended by the manufacturer, which shall be verified by weight testing during construction according to Paragraph 5.05B.

4. The submitted test data required in Table 1 will be evaluated statistically by the EOR to determine the characteristic values. (The characteristic value of a strength or modulus property corresponds to the fifth-percentile value with 80% confidence. It is determined from a sample size of ten or more according to ASTM D7290.)

5. For each property, outliers will be removed from each data set. Any remaining data set with fewer than five samples will be discarded.

6. Statistical tests will be performed to determine whether the remaining data sets can be combined. If all data sets cannot be combined, several combined data sets will be formed with the maximum possible number of samples, but not fewer than ten. If no combined data sets can be formed with ten or more samples, data will be rejected. In the case of more than one combined set with a comparable number of samples, the smallest characteristic value will be selected as the overall characteristic value of the material property.

7. The physical properties of CFRP shall be determined using the ASTM standard test methods specified in Table 2 and shall be equal or greater than the minimum values listed in Table 2.

8. The watertightness testing results shall be provided for the design CFRP layup in accordance with Paragraph 4.02D.

Table 1 – Minimum Mechanical Property RequirementsMechanical PropertyMinimum RequirementASTM Test MethodMinimum Number of TestsTensile Strength8x104 psiD303950 from 5 different lotsTensile Modulus8x106 psiD303910Compressive Strength4x104 psiD664110Compressive Modulus8x106 psiD664110Flexural Strength1.5x104 psiD79010Flexural Modulus0.35x106 psiD79010In-plane Shear Strength1.2x104 psiD537910In-plane Shear Modulus0.40x106 psiD537910Interlaminar Shear Strength4x103 psiD234410Overlap Shear Strength1.2x103 psiD761610Tensile Strength of Epoxy650 psiD63810Compressive Strength of Epoxy6.5x103 psiD69510 Table 2 – Minimum Physical Property TestsPhysical PropertyRequirementASTM Test MethodMinimum Number of TestsGlass transition temperature (Tg) of resinGreater than maximum of exposure temperature +40°F and 175°FD4065, D3418, or E164020Volatile organic compoundsIn compliance with state and local regulationsD23692Water absorption of fully cured resinLess than 2% at room temperatureD5705CFRP thickness per layerMinimum of 0.04 in. per layer & Maximum of 0.08 in. per Layer NominalPer Manufacturer data sheet10

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D. Required Datasheet Information:

1. The Contractor shall provide Manufacturer’s product data sheets providing the following data as a minimum, to be reviewed by the EOR and approved by the Owner:

a. Compliance with NSF/ANSI 61.

b. List of all constituent materials used in the CFRP system and purpose of each.

c. The physical and mechanical properties of the CFRP and of its constituent materials.

d. Tensile strength and modulus of the CFRP system and their characteristic values calculated in accordance with ASTM D7290.

e. Compressive strength and modulus of the CFRP system and their characteristic values calculated in accordance with ASTM D7290.

f. Tensile and compressive strengths of epoxy and their characteristic values calculated in accordance with ASTM D7290.

g. Poisson's ratio in the fiber and transverse directions.

h. Fiber weight (ounce per square yard or gram per square meter).

i. Nominal thickness per layer.

j. Coefficient of thermal expansion in the fiber and transverse directions.

k. Glass transition temperature (Tg) of cured resins.

l. Time-temperature-degree of cure relationships for the resins. The test data indicate percent completion of cure (ASTM E2160) versus temperature and duration.

m. Volatile organic compounds (VOCs) for resins.

n. Fiber-to-resin ratio and tolerance.

o. Resin mixing instructions.

p. Pot life at ambient temperature and humidity conditions.

q. Approximate resin coverage rate.

r. Shelf life.

s. Handling, transportation and storage requirements.

t. General installation instructions, including surface preparation requirements.

u. Packaging information.

v. Safety information, including Manufacturer’s Safety Data Sheets (SDS) for all materials to be used and Manufacturer’s documents indicating that all materials meet OSHA, EPA, and local ordinances for health and safety, including VOC compliance.

w. Approved/valid Internation Code Council (ICC) Evaluation Service Report (ESR) must be available for the proposed CFRP composite system.

2. Warranty:

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3. The terms of the Manufacturer’s warranty shall be specified by the Owner in the contract with the Contractor.

E. Training Support:

1. The Manufacturer shall support a training program to instruct the Installer in the installation of their CFRP system presented to meet this Specification.

II. QUALIFICATIONS OF INSTALLER

A. Experience and Certification:

1. The Installer shall have successful installation of CFRP system for pipe repairs similar to those described in these Specifications and shown on the design Drawings, on a minimum of twenty-five pressurized concrete pressure pipe projects used for internal water pipeline rehabilitation including CFRP layers and epoxy within the past five (5) years, documented with client contact information and a summary of work performed in each project. For a project to be considered applicable, it must involve the following: internal application of CFRP on pipelines greater than 30in diameter, with pressures greater than 50psi operating pressure, where the same CFRP system proposed for use on this project has been used as a stand-alone upgrade of the pipeline without reliance on the host pipe for structural integrity. The minimum project length shall be 20 lineal feet of repair.

2. The Installer crews for each area of Work performed, including pipe surface preparation, mixing of materials, impregnation of fabrics, and installation of impregnated fabrics, shall include Executive Project Manager, Project Manager, Superintendent, and two (2) Foreman available with a minimum of five yrs’ experience and a minimum of twenty-five projects in internal CFRP repair of large diameter concrete pressure pipe, with at least one (1) being over 1,000 lineal feet of continuous renewal using CFRP per worker. The Installer shall provide a list of reference projects for all crew members.

3. All crew members shall have received training from the Manufacturer with documented experience and written verification that the CFRP Installer personnel are trained and certified in the use of the proposed CFRP system.

4. The Installer shall have a quality control program and shall agree to have field QC inspectors (referred to herein as Contractor’s Inspectors) on site throughout the project execution (one at the material preparation site above ground, and one at the application site inside the pipe). Contractor’s Inspectors shall be qualified according to Paragraph 3.03A.

5. The Installer shall have a health and safety plan in compliance with the site-specific requirements and the contract issued by the Owner.

6. The Installer shall have a noise abatement plan for equipment needed to support ventilation and dehumidification of the pipeline throughout the CFRP installation and curing, in compliance with the Owner’s site-specific requirements and the contract issued by the Owner.

B. Warranty:

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1. The terms of the Contractor’s warranty shall be specified by the Owner in the contract with the contractor.

III. QUALIFICATIONS OF CONTRACTOR’S INSPECTOR

A. Contractor’s Inspectors shall have completed the training program supported by the Manufacturer on the installation of bonded CFRP systems and shall have experience on at least twenty projects in the last five years involving CFRP application in pipeline confined spaces.

B. Any change of Contractor’s Inspectors is subject to the same qualifications.

C.7. PRODUCTS CFRP SYSTEM

I. CFRP SYSTEM

A. The CFRP system shall consist of epoxy primer, thickened epoxy (i.e., putty), unidirectional carbon fabric, impregnating epoxy resin, and topcoat. Resin types other than epoxy (e.g., polyester, vinyl ester) shall not be used as any of these components.

B. The CFRP System shall conform to the requirements of NSF/ANSI 61 for safe drinking water system component.

C. Primer

1. The concrete substrate shall be primed with an epoxy material, which shall penetrate the pore structure of the substrate. The primer shall be a 100% solids, epoxy resin.

2. The glass-transition temperature and water absorption requirement of Paragraph 3.01C.5 also apply to the primer.

D. Thickened Epoxy

1. Thickened epoxy shall have a high enough viscosity to fill all voids in the concrete substrate and provide a smooth base for the subsequent CFRP laminates.

2. Thickened epoxy shall either be preformulated and brought to site in pre-proportioned containers or prepared on site by mixing the impregnating resin with Cab-O-Sil TS-720 treated fumed silica to achieve the required viscosity. If prepared on site with Cab-O-Sil, the Contractor shall obtain the Contractor’s Inspectors’ and Owner’s Inspector’s approval prior to any use.

3. The glass-transition temperature and water absorption requirement of Paragraph 3.01C.5 also apply to the thickened epoxy.

E. Impregnating Resin

1. All fabrics shall be impregnated with 100% solids, low-viscosity epoxy resin.

2. The impregnating resin shall meet the glass-transition temperature and the water absorption requirement of Paragraph 3.01C.5.

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3. The CFRP system shall use a two-component epoxy with the following mechanical properties obtained according to ASTM D638 at 72-degree Fahrenheit and 40% relative humidity and reported by the Manufacturer:

a. Maximum water absorption when tested in accordance with ASTM D570 (24 hours): 2 percent

b. Tensile modulus: 300 ksi

c. Minimum flexural strength when tested in accordance with ASTM D790 (14-day cure):

7,500 psi

F. Unidirectional Carbon Fiber-Epoxy Laminates

1. The CFRP repair designs shown on the design drawings are based on the following CFRP characteristic properties listed below. The Contractor using a different product or a batch of the same material with lower characteristic properties as listed below, shall submit documentation demonstrating the noncompliant properties to the Owner for review and if needed redesign by the EOR.

a. Carbon Fiber Fabrics (38 oz/sq yd)

i. Nominal thickness per layer = 0.08 in.

ii. Characteristic tensile strength = 152.2 ksi.

iii. Characteristic ultimate tensile force per unit width = 12.2 kip/in.

iv. Characteristic tensile modulus = 12,312 ksi.

G. Required Properties of Unidirectional Carbon Fiber-Epoxy Laminates:

1. The unidirectional carbon fiber-epoxy laminate shall meet the requirements of Paragraph 3.01C and those shown on the Design Drawings.

2. The tensile properties of the CFRP lamina to be used in design shall be determined according to ASTM D3039 and statistically analyzed according to ASTM D7290 to determine the characteristic values.

3. The CFRP designs shown on the drawings are based on the characteristic properties for one layer of CFRP. CFRP systems other than those shown on the drawings shall be reviewed by the EOR and approved by the Owner and used to calculate the required number of layers.

4. The characteristic values for multi-layer laminates shall be based on the reduction in strength due to the strength variability and redistribution of stresses of a failed lamina among other layers using strain compatibility.

II. GFRP (GLASS FIBER-REINFORCED POLYMER) LAYER

A. The CFRP Repair System shall include a GFRP system used as insulator between the steel substrate and the CFRP layer and may include a second system for watertightness.

B. All components of the GFRP composite system shall be provided by the same Manufacturer as the CFRP system.

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C. The GFRP composite layer shall be used as insulator between any steel components and

CFRP to avoid possible galvanic corrosion, and shall have a total nominal thickness of a single GFRP lamina of not less than 0.01 in.

D. The GFRP layer used for watertightness or watertightness coating used in lieu of the GFRP layer shall be successfully tested with the design laminate or a laminate that is part of the design laminate.

1. A minimum of three samples of the CFRP laminate shall be tested.

2. Tests shall be conducted using the samples, apparatus and protocol comparable to those defined in the Water Research Foundation Report #4592, or using other apparatus or procedures reviewed by the EOR and approved by the Owner.

3. The minimum pressure at which the test samples leak or rupture shall be 400 psi.

III. PROTECTIVE COATING (TOP COAT)

A. The Contractor shall ensure the following:

1. The CFRP system shall be top-coated with a coating recommended by the CFRP system manufacturer and in conformance with the following:

a. The topcoat shall consist of the same thickened epoxy used between the CFRP layers or potable water coating, if needed.

b. Seams in fabric and edges shall be smoothened with thickened epoxy prior to application of the topcoat.

c. The topcoat material shall have been used successfully as a finished assembly on a minimum of five past documented concrete pressure pipe pipe strengthening projects.

2. Topcoat shall be installed in accordance with the Manufacturer’s published installation instructions. The duration elapsed between the application of the last CFRP layer and the topcoat shall not exceed the time specified by the Manufacturer.

IV. OTHER MATERIALS

A. Epoxy Mortar

1. The Contractor shall ensure that epoxy mortar consists of five parts epoxy resin mixed with one part sand or equivalent demonstrated to have the ability to bond to concrete, steel, and CFRP in overhead and all other positions. The Contractor shall obtain the Contractor’s Inspectors’ and Owner’s Inspector’s approval on the consistency of the epoxy mortar prior to any use.

2. Apply epoxy mortar in multiple lifts with a maximum thickness per lift of half the thickness of concrete inner core. After the epoxy mortar is tack free, perform visual and sounding inspection around the entire circumference to ensure no sags, voids, or cracks in the epoxy mortar. In case of any anomalies, contact the Owner and the EOR for remedial actions.

B. Bond Breaker

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1. Where indicated on the design drawings, the Contractor shall provide a bond-breaker material consisting of one of the following:

a. 100% acrylic elastomeric coating.

b. Paraffin wax.

c. Approved equivalent of the above.

C. Stainless Steel Expansion Ring Used at Termination of New CFRP Liners

1. A single WEKO-Seal stainless steel expansion ring, or approved equivalent, with a 1/4 in.

rubber strip, installed according to the repair drawings using the equipment and jacking pressures recommended by the manufacturer. All expansion rings, wedges, and shims shall conform to the grade recommended by the Manufacturer for the expected exposure condition and to ASTM A240.

D. WEKO Seals Used at Joints Between Pipes with New and Existing CFRP Liner

1. Extra-wide or double-wide WEKO Seal or equivalent approved by the Owner, installed according to the repair drawings using the equipment and jacking pressures recommended by the manufacturer. All expansion rings, wedges, and shims shall conform to the grade recommended by the Manufacturer for the expected exposure condition and to ASTM A240.

V. DELIVERY, STORAGE, AND HANDLING OF ALL MATERIALS

A. The Contractor shall ensure the following:

1. Delivery

a. The products shall be delivered in original, unopened containers. Containers shall be clearly marked with legible and intact labels listing the Manufacturer’s name, brand name, product identification, batch number, storage conditions, mixing ratios, and shelf life.

2. Storage

a. All Contractor materials and equipment shall be stored in areas designated by the Owner and using access locations designated by the Owner.

b. Contractor shall ensure that materials are stored at temperatures that conform to Manufacturer's written recommendations and instructions.

c. Stored fiber reinforcement and resins shall be protected from dust, moisture, and chemical exposure.

d. Resin components shall be stored separately and in tightly closed containers, away from direct sunlight, flame sources, or other hazards.

e. In the event that Work is to be completed during winter or in temperatures below freezing, the fiber reinforcement and resins shall not be exposed to freezing temperatures during transport, storage, preparation, installation, or curing. In the event that Work is to be performed during summer, the fiber reinforcement and resins shall

BUSINESS SERVICES DEPARTMENT Page 19 of 104 not be exposed to temperatures above the maximum storage temperature recommended by the manufacturer. To achieve protection against hot and cold temperatures, the Contractor shall provide temporary portable heating or cooling using equipment reviewed and approved by the Owner prior to use.

3. Handling

a. The fabric reinforcement shall not be handled roughly. Care shall be taken not to damage the fibers.

b. Fabric reinforcement may be stored either in rolls of 4 in. radius or greater or stacked after cutting.

c. Consult the Manufacturer’s SDS for specific handling hazards of resin components.

C.8. EXECUTION

I. GENERAL PROCEDURES

A. Work only in areas permitted by Owner-approved schedule.

B. Remove all tools, buckets, and materials from work areas and store neatly at a designated location daily at the end of work.

C. Protect adjacent areas from damage, stains, and spillage during delivery of material to repair areas. Repair all damage resulting from the performance of Work and return it to its condition at the start of work, or if such cannot be determined, to its original condition. Clean all stains by means approved by the Owner.

D. Protect Work from damage such as impact, marring of the surfaces, and other damage.

E. After surface preparation, maintain the repair surfaces and nearby pipe surfaces clean and clear of all dusts and debris that can contaminate the wet surfaces and result in poor interlaminar bond strength.

F. Materials may be skin irritants or sensitizers. Accordingly, advise system installer to avoid contact with eyes and skin, inhalation of vapors, and ingestion. Use protective and safety equipment on site. Heed all label warnings by manufacturers. Make application in accordance with applicable safety laws.

G. The Contractor, his Subcontractor(s), suppliers, consultants, and workers shall maintain a safety program that follows the site-specific requirements and contract issued by the Owner.

H. Comply with all site-specific requirements for hazardous materials. Prevent hazardous accumulations of dusts, fumes, mists, vapors, or gases in areas occupied during construction.

Provide local exhaust ventilation to prevent harmful dispersal of hazardous substances into atmosphere of occupied areas. Dispose in a manner that will not result in harmful exposure to persons. Ventilate storage spaces containing hazardous or volatile materials. Provide dust and fume control, including, but not limited to, temporary protection and confinement barriers, ventilation equipment and procedures, and air-quality-monitoring equipment and procedures.

Monitor air quality in the work area and inside the pipeline.

I. Ventilation inside the pipeline shall be per site-specific requirements, including, but not limited to, permit required confined space entry and underground construction.

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II. INSPECTION OF HOST CONCRETE PRESSURE PIPE

A. The Inspectors shall examine the existing conditions to verify dimensions/geometry shown on drawings, assess quality of concrete substrate, document any cracks, ovality, or surface irregularities in the pipe, identify any leaks near repair areas and evaluate water retention plans (as necessary) of the Contractor/Installer, and evaluate risk of exposure of CFRP to water prior to cure. The concrete shall be sound and without standing water.

B. The Inspectors shall also examine the aboveground conditions under which materials will be stored, mixed, and transported into the pipe and specify corrective actions as necessary.

C. The Contractor/Installer shall correct all unsatisfactory conditions and obtain the approvals of Contractor’s Inspector, Owner’s Inspector, the EOR, and the Owner prior to commencement of repairs.

III. PREPARATION

A. The Contractor/Installer shall ensure the following:

1. Environmental Conditions

a. Do not install CFRP when the ambient temperature or relative humidity is outside the range required by the Manufacturer, or the concrete surface temperature is less than 5°F above the dew point. In cold conditions, auxiliary heat may be applied to raise the ambient temperature to a suitable level. If heating is used, direct-fired gas or kerosene salamander-type heaters shall not be permitted. Only electric or indirect-fired heaters shall be permitted, to avoid contaminating the substrate with carbonation.

b. The presence of water inhibits the adhesion of epoxy to the substrate. Do not install CFRP when surface moisture is present. Use dehumidifiers to keep the relative humidity within the range required by the Manufacturer. There shall be no standing water in the pipe.

c. If water leakage exists through cracks or joints, water flow shall be stopped prior to CFRP installation.

2. Site Conditions

a. The Contractor/Installer shall comply with site-specific Confined Space entry procedure.

b. The Installer shall maintain control of concrete chips, dust, and debris due to mortar lining repair or surface preparation in each area of work. The Installer shall clean up and remove such material at the completion of work each day.

C.9. INSTALLATION

I. CONCRETE SUBSTRATE REPAIR/RESTORATION

A. The Contractor/Installer shall ensure the following:

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1. All problems associated with the condition of the original concrete and the concrete substrate that can compromise the integrity of the CFRP system shall be addressed before surface preparation begins. The Contractor/Installer shall ensure adherence to Manufacturer’s requirements regarding compatibility of the CFRP system with materials used for repairing/restoring the substrate. The Contractor shall provide supporting information regarding compatibility to the Owner for review and approval by the EOR and the Owner.

2. Voids in the substrate shall be filled. Small voids no more than 0.50 in. in depth shall be filled with a thickened epoxy and larger voids with epoxy mortar.

B. Surface Preparation for Concrete and Steel Substrates

1. The Installer shall first prepare representative mockup areas on surface of concrete as specified in Paragraph 5.04F.2. Such areas shall be prepared in accordance with the requirements of this Specification and the Manufacturer’s written instructions, and shall be used as a reference standard depicting a satisfactorily prepared substrate. The concrete surface shall be profiled using hydro surface profiling or other abrasive blasting to remove all contaminants (laitance, surface lubricants, broken mortar pieces, etc.) and to achieve a minimum profile of ICRI CSP 3 (refer to ICRI Guideline No. 310.2R and molded replicas of surface textures that can be obtained from ICRI).

2. The concrete or repaired/restored surfaces to which the CFRP system is to be applied shall be freshly exposed and free of loose or unsound materials, and shall be allowed to dry prior to CFRP installation.

3. Localized out-of-plane variations, such as form lines, sharp edges, and protrusions, shall not exceed 1/4 in. Such out-of-plane variations can be removed by grinding or abrasive blasting, or can be smoothed over using thickened epoxy if variations are very small.

4. All debris and dust generated during surface preparation shall be removed by air blasting or other approved means to achieve a dust-free concrete surface.

5. At areas where the GFRP systems will be adhered directly to the steel, such as CFRP repair terminations, prepare the surface for the length specified to SSPC SP-10 near-white surface using abrasive blasting prior to installing the CFRP system. Perform visual inspection of the prepared surface to verify that no through holes or other anomalies exist after sandblasting. Any puncture or through hole in the steel cylinder shall be repaired by welding. The welder shall be an AWS-certified welder.

C. Mixing of Resins

1. The resin and its catalyst shall be kept in tightly closed containers at all times except for the time of mixing to prevent absorption of carbon dioxide and moisture. The mixing technique shall not cause air entrainment in the resin system.

2. All resins shall be mixed according to the Manufacturer’s instructions. All resin components shall be at a proper temperature and mixed from pre-proportioned and pre-packaged containers until there is a uniform and complete mixing of components. On-site proportioning of resin components is not allowed. Resins shall be mixed for the Manufacturer’s prescribed mixing time and visually inspected for uniformity of color.

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3. Mixed resin that exceeds the pot life specified by the Manufacturer shall not be used.

D. Application of CFRP System

1. The application of the CFRP system shall be performed in accordance with the Manufacturer’s published installation instructions.

2. The CFRP system primer shall be applied to all areas on the existing concrete surface where the CFRP system is to be placed. The primer shall be placed uniformly on the prepared surface at the Manufacturer’s specified rate of coverage. Subsequent materials shall be applied within the time window specified by the Manufacturer.

3. Following the primer, all voids in the substrate shall be filled to achieve a smooth surface using thickened epoxy.

4. All fabrics shall be impregnated using a mechanical saturation machine.

5. Pre-cured laminates, dry layup or manual impregnation is not allowed.

6. The impregnated fabric shall be pressed onto the concrete surface to achieve intimate contact. Entrapped air between layers shall be released or rolled out before the resin sets.

7. A thin layer of thickened epoxy shall be applied between all consecutive…