Attachment 7 - Amended Task 1 Statement of Work.pdf

1 | P a g e FDA_20-223-1224034 - Attachment #7 - Amended Task 1

AMENDED STATEMENT OF WORK

CURED IN PLACE PIPE (CIPP)

(Task 1)

A. GENERAL

It is the intent of this specification to provide for the reconstruction of pipelines and conduits by the installation of a resin-impregnated fiberglass material tube (“Liner”) which when cured shall extend the full length of the original pipe and provide a structurally sound, smooth, jointless and watertight pipe. The resin shall be cured using ultraviolet light within the tube. The Cured-In- Place Pipe (CIPP) will be continuous and tight fitting.

B. REFERENCED DOCUMENTS

The following documents form a part of this specification to the extent stated herein:

1. ASTM F2019 Standard Practice for Rehabilitation of Existing Pipelines and Conduits by the Pulled in Place Installation of Glass Reinforced Plastic (GRP) Cured-in-Place Resin Pipe (CIPP)

2. ASTM F1216 Standard Practice for Rehabilitation of Existing Pipelines and Conduits by the Inversion and Curing of a Resin-Impregnated Tube

3. ASTM F1743 Standard Practice for Rehabilitation of Existing Pipelines and Conduits by the Pull-In and Inflate and Curing of a Resin-Impregnated Tube.

4. ASTM D543 Test Method for Resistance of Plastics to Chemical Reagents

5. ASTM D578 Standard Specification Glass Fiber Strands

6. ASTM D638 Standard Test Method for Tensile Properties of Plastics

7. ASTM D790 Standard Test Methods for Flexural Properties of Unreinforced and

Reinforced Plastics and Electrical Insulating Materials

8. ASTM D2122 Standard 1 Test Method for Determining Dimensions of Thermoplastic

Pipe and Fittings

9. ASTM D3567 Standard Practice for Determining Dimensions of “Fiberglass” (Glass

Fiber-Reinforced Thermosetting Resin) Pipe and Fittings

10. ASTM D5813 Standard Specification for Cured-in Place Thermosetting Resin Sewer

Pipe

C. PRODUCT QUALIFICATION REQUIREMENTS

The provided product shall have a 50-year design life, and in order to minimize the Owner’s risk, only proven products with substantial successful long-term track records will be approved.

Products and Installers must meet all of the following criteria to be deemed Commercially Acceptable:

2 | P a g e FDA_20-223-1224034 - Attachment #7 - Amended Task 1

1. The Manufacturer shall have a minimum 500,000 linear feet of successfully installed liner in the United States of America with the same product being used on this project.

The installing Contractor must be trained and certified by the UV GRP manufacturer and have documented experience with a fiberglass UV cured liner.

2. For each method of installation and curing used on this project, the Cured-In-Place Pipe Lining (CIPPL) work shall be supervised by a foreman having previously supervised a minimum of 50,000 linear feet of CIPPL using a similar resin and flexible tube and using the specific method of installation and curing method proposed.

3. The manufacturer of the glass reinforced tube, including wet out, of the CIPPL shall have been performing this same type of work with ultra violet cured glass reinforced pipe (UV GRP) for a minimum of five years and previously wet-out at least 500,000 linear feet of this same technology. If the Contractor does not have 50,000 linear feet of CIPPL experience with the UV curing system being used, then a manufacturer’s onsite representative must be present during installations of the CIPP system until such time the owner is confident in the Contractor’s ability. The Contractor is to provide the FDA with the manufacturer representative’s work experience for approval. Work shall not begin prior to the FDA’s approval of the manufacturer’s onsite representative.

4. The Contractor shall provide references of completed projects of similar installations.

5. The Contractor shall provide a summary table of CIPP material properties, including short-term flexural modulus of elasticity, 50-year flexural modulus of elasticity, short-term flexural strength (bending stress), 50-year flexural strength (bending stress), and chemical resistance. Certified test reports shall be submitted verifying each value as described below.

6. Independent third-party certified laboratory test reports demonstrating that the exact resin/liner combination to be used for this project meets the requirements for initial structural properties and chemical resistance (performed in accordance with ASTM F1216).

7. The name of the liner and resin manufacturer, the location of the facility where each was manufactured, and a list of appurtenant materials and accessories to be furnished.

8. All lining work shall be fully guaranteed by the Contractor for a period of one (1) year from the date of Final Acceptance unless otherwise stipulated in writing by the FDA prior to the date of Conditional Acceptance. During this period, all serious defects discovered by the FDA shall be removed and replaced by the Contractor in a satisfactory manner at no cost to the FDA. In addition, the FDA may conduct independent television inspections, at its own expense, of the lining Work at any time prior to the completion of the guarantee period.

9. Available standard written warranty from the manufacturer.

3 | P a g e FDA_20-223-1224034 - Attachment #7 - Amended Task 1

D. INSTALLER/BIDDER PREQUALIFICATION REQUIREMENTS

In order for Installers/Bidders to be approved they shall have active experience in the commercial installation of the exact product bid. The Installer/Bidder must have experience in installing a minimum of 50,000 linear feet of CIPPL.

E. MATERIALS

Fiberglass Liner – At the time of manufacture, each lot of glass fiber tube liner shall be inspected for defects. At the time of delivery, the liner shall be homogeneous throughout, uniform in color, free of cracks, holes, foreign materials, blisters, and deleterious faults.

The FDA may at any time may direct the manufacturer to provide compound samples and prepare test specimens in accordance with the latest applicable ASTM standards.

Cured-in-Place-Pipe – The glass fiber tubing shall include an exterior and interior film that protects and contains the polyester, vinylester or ortho based resin used in the liner. The exterior film shall be provided with a UV light blocker foil.

Tube:

1. The wet-out tube shall have a uniform thickness that when compressed at installation pressures will meet or exceed the design thickness.

2. The tube shall be sized such that when installed, will tightly fit the internal circumference and length of the original pipe.

3. The glass fiber tube shall be saturated with the appropriate resin using a resin bath system to allow for the lowest possible amount of air entrapment. An inner and outer material will be added that are both impervious to airborne styrene, with the outer material also having UV blocking characteristics. If required by the liner manufacturer, the inner membrane will be removed after the installation and curing processes are completed.

4. The wall color of the interior pipe surface of CIPP after installation shall be a light reflective color so that a clear detailed examination with closed circuit television inspection equipment may be made.

5. The liner should be seamless in its cured state to ensure homogenous physical properties around the circumference of the cured liner.

Resin:

4 | P a g e FDA_20-223-1224034 - Attachment #7 - Amended Task 1

1. The resin system shall be polyester, vinylester, or orthothalic (either ppg or npg grade) depending on the choice of the FDA/Contractor, with a catalyst system that when properly cured within the tube composite meets the physical properties of:

a. Flexural Modulus (minimum): 725,000 psi

b. Flexural Strength (minimum): 15,000 psi

c. Long Term E-Modulus: 675,000 psi

d. Long Term Tensile Bending Strength: 13,500 psi

2. The resin used with this product shall use UV light to cure the pipe. The liquid UV resin shall saturate the tube and produce a properly cured liner, which is resistant to abrasion due to solids, grit, and sand.

3. Polyester, vinyl ester and catalyst system shall comply with the following requirements and when properly cured meet the requirements of ASTM F1216. Resins created from recycled materials are not allowed.

Adheres to ASTM F 2019-11 (or latest edition)

F. STRUCTURAL REQUIREMENTS

1. The CIPP shall be designed as per ASTM F1216, Appendix X.1. The CIPP design shall assume no bonding to the original pipe wall.

2. The CIPP shall be designed in accordance with the design equations in ASTM F1216 and the design parameters and physical properties listed within these specifications.

3. The Contractor must have performed long-term testing for flexural creep of the CIPP pipe material installed by their Company. Such testing results are to be used to determine the long-term, time dependent flexural modulus to be utilized in the product design. This is a performance test of the materials (Tube and Resin) and general workmanship of the installation and curing. A percentage of the instantaneous flexural modulus value (as measured by ASTM D790 testing) will be used in design calculations for external buckling. The percentage, or the long-term creep retention value utilized, shall be verified by this testing. Values in excess of 50% shall not be applied unless substantiated by qualified third-party test data. The material utilized for the contracted project shall be of a quality equal to or better than the materials used in the long-term test with respect to the initial flexural modulus used in design.

4. The layers of the cured CIPP shall be uniformly bonded. It shall not be possible to separate any two layers with a probe or point of a knife blade so that the layers separate cleanly or the probe or knife blade moves freely between the layers. If separation of the layers occurs during testing of field samples, new samples will be cut from the work. Any reoccurrence may cause rejection of the work.

5 | P a g e FDA_20-223-1224034 - Attachment #7 - Amended Task 1

5. The cured pipe material (CIPP) shall have a minimum modulus of elasticity using test method ASTM D790 of 400,000 psi per ASTM F1216.

6. The cured pipe material (CIPP) shall have a minimum flexural stress using test method ASTM D790 of 4,500 psi per ASTM F1216.

7. The required structural CIPP wall thickness shall be based as a minimum, in accordance with the Design Equations in ASTM F1216 (plus 10% rounded up to the nearest 1.5mm manufacturing increment), and the following design parameters:

a. 50-year design life

b. Host pipe fully deteriorated offering no structural support

c. 2.0 minimum factor of safety

d. Soil modulus of 700 psi

e. Ovality factor – as encountered, 10% max., 2% min. (design)

f. Retention factor for long term flexural modulus to be utilized in design = 50% to

75% (as determined by long term tests described above).

g. Maximum water depth equal to minimum depth of cover over existing pipe.

h. Soil density = 120 pcf

i. Surface live load = H20 highway minimum

j. Resin Migration Allowance is NOT allowed.

k. Maximum deflection of 5%.

8. Contractor shall supply upon request copies of thickness design calculations to the FDA for review and approval. In the event that the thickness the Bidder / Contractor calculates is less than that calculated by the FDA, the Bidder / Contractor shall supply the thickness specified by the FDA in accordance with these specifications. Any layers of the tube that are not saturated with resin prior to insertion into the existing pipe shall not be included in the structural CIPP wall thickness computation.

9. UV GRP cured-in-place pipe system shall utilize resins which will withstand the corrosive effect of the existing residential, commercial, and industrial effluents, liquids and/or gases.

G. QUALITY CONTROL

1. No change of material, design values, or procedures as developed before bidding the contract may be made during the course of the Work without the prior written approval of the FDA.

2. All liner to be installed under this Work may be inspected at the manufacturer’s plant(s) and wet-out facility for compliance with these Specifications by FDA. The Contractor shall require the wet-out facility's cooperation in these inspections. The cost of inspection will be the responsibility of the FDA.

6 | P a g e FDA_20-223-1224034 - Attachment #7 - Amended Task 1

3. At the time of delivery, the liner shall be homogeneous throughout, uniform in color, free of cracks, holes, foreign materials, blisters, or deleterious faults.

4. The liner manufacturer facility shall have a Quality Management System registered with the current ISO 9001 standard.

5. The wet-out of the liner must be done in an indoor environmentally controlled manufacturing setting. No onsite wet-out will be allowed.

H. INSTALLATION RESPONSIBILITIES FOR INCIDENTAL ITEMS

It shall be the responsibility of the Government to locate and designate all manhole access points open and accessible for the work, and provide rights of access to these points. The Contractor shall be responsible for the maintenance of traffic in the project area. Traffic disruption shall be kept to a minimum and meet with the Government’s approval. The Government shall also provide access to water hydrants for cleaning, inversion and other work items requiring water.

Cleaning of Sewer Lines – The Contractor shall remove all internal debris from the sewer line that will interfere with the installation of CIPP (this condition is typically considered to be ALL internal debris). The Contractor shall contain all debris removed from the sewers during the cleaning operation and properly dispose. Prior to access, the Contractor shall submit an Authorization for Disposal of Liquid Waste Form to the Utility along with the $250.00 permit fee.

Any hazardous waste material encountered during this project will be considered as a changed condition. The extent of the cleanness of the sewer line shall meet approval of the Government before installation of the CIPP.

Bypassing Sewage – The Contractor shall provide for the flow of sewage around the section or sections of pipe designated for repair. The bypass shall be made by plugging the line at an existing upstream manhole and pumping the flow into a downstream manhole or adjacent system. The pump and bypass lines shall be of adequate capacity and size to handle the flow.

No release of untreated sewage shall be allowed. Any such unauthorized release shall be the entire responsibility of the Contractor. The Contractor shall submit a detailed bypass-pumping plan to the Government before work has begun.

Inspection of Pipelines – Inspection of pipelines shall be performed by experienced personnel trained in locating breaks, obstacles and service connections by close circuit television. After initial cleaning and prior to installation of CIPP into pipelines, the interior of the pipeline shall be carefully video inspected to determine the location of any conditions which may prevent proper installations of the CIPP into the pipelines, and it shall be noted so that these conditions can be corrected. All service (branch) connections shall be identified as being active or inactive and so noted on the pre-installation video(s). The use of dye and running water will be necessary to identify active service lines. Each and every structure in the area of the work shall be confirmed as to whether its service line drains into the pipeline to be rehabilitated or drains elsewhere.

Special attention is needed for structures which may have more than one service connection

7 | P a g e FDA_20-223-1224034 - Attachment #7 - Amended Task 1 due to add-ons or additions constructed with separate service laterals. A post-installation/post-service line reconnection video inspection shall also be performed. A copy of all pre-installation and post-installation video(s) and log(s) shall be provided to the Government. All video shall be provided to Government in DVD format. Each DVD shall be clearly labeled as to the Government’s name, project name, date of video, location of video, line size, and Contractor’s name. Written logs shall accompany each video.

Line Obstructions – It shall be the responsibility of the Contractor the clear the line of obstructions such as solids and roots that will prevent the insertion of the CIPP. If preinstallation inspection reveals an obstruction such as a protruding service connection, dropped joint, or a collapse that will prevent the inversion process, and it cannot be removed by conventional sewer cleaning equipment, then the Government shall make a point repair excavation to uncover and remove or repair the obstruction or issue a change order for needed repairs. Such excavation shall be approved in writing by the Government’s representative prior to the commencement of the work and shall be considered as a separate pay item.

Public Notification – The Contractor shall make every effort to maintain service usage throughout the duration of the project. In the event that a sewer service will be out of service, the Contractor shall provide for bypass pumping of that service so that the customer may maintain use of their sewer service. A public notification program shall be implemented, and shall as a minimum, require the Contractor to be responsible for contacting each facility connected to the sanitary sewer and informing them of the work to be conducted, and when the sewer service will be off-line.

The Contractor shall be responsible for confirming the locations of all service (branch) connections prior to inversion and curing the CIPP. All service (branch) connections shall be identified as being active or inactive.

I. INSTALLATION

1. The approved system shall utilize an outer and inner film to ensure that the liner remains intact during the insertion process and to protect the resin at all times during the installation and curing process from water and debris contamination, and resin migration.

2. A constant tension winch should be used, as specified by the liner manufacturer, to pull the glass fiber liner into position in the pipe. The liner shall have a longitudinal fiberglass reinforcement band which runs the entire length of the liner ensuring that the pulling force is transferred to the band and not the fiberglass liner. Once inserted, end plugs (caps) shall be used to cap each end of the glass fiber liner to prepare for pressurizing the liner. The end plugs shall be secured to prevent them from being expelled due to pressure. Liner restraints shall be used in manholes.

3. slip sheet shall be installed on the bottom one third to one half of the pipe prior to liner insertion (if it is not already part of the manufactured outer film of the liner), for the

8 | P a g e FDA_20-223-1224034 - Attachment #7 - Amended Task 1 purpose of protecting the liner during insertion and reduce the drag, or as recommend by the liner manufacturer.

4. The glass fiber liner shall be cured with UV light sources at a constant inner pressure.

When inserting the curing equipment in the liner, care shall be taken to not damage the inner film material.

5. The UV light sources shall be assembled according to the manufacturer’s specifications for the liner diameter. For the liner to achieve the required water tightness and specified mechanical properties, the following parameters must be controlled during the entire curing process, giving the FDA a record of the curing parameters over every segment of the entire length of the liner. This demonstrates that the entire liner is cured properly.

The recording shall include:

a. Curing speed

b. Light source working & wattage

c. Inner air pressure

d. Curing temperatures

e. Date and time

f. Length of liner

6. This shall be accomplished using a computer and database that are tamper proof.

During the curing process, infrared sensors shall be used to record curing data that will be submitted to the FDA with a post CCTV inspection.

7. The optimal curing speed, or travel speed of the energized UV light sources, is determined for each length of liner based on liner diameter, liner thickness, and exothermic reaction temperature. Curing speed shall be as recommended by the manufacturer and determined by Contractor based on various site-specific field conditions.

8. If the liner is manufactured with a removable inner film, the inner film material shall be removed and discarded after curing to provide optimal quality of the final product.

J. REINSTATEMENT OF SERVICE (BRANCH) CONNECTIONS

It is the intent of these Specifications that service (branch) connections to buildings be reopened without excavation, utilizing a remotely controlled cutting device, monitored by a video TV camera. The Contractor shall certify he has a minimum of two (2) complete working cutter units plus spare key components on the site before each inversion. No additional payment will be made for excavations for the purpose of reopening connections and the Contractor will be responsible for all costs and liability associated with such excavation and restoration work. Service connections shall be restored to 90% of the full diameter. The restored opening shall be clean and free of burrs or projections that may catch debris. The coupon or shavings resulting from the reconnection process shall be removed or flushed from the pipeline.

9 | P a g e FDA_20-223-1224034 - Attachment #7 - Amended Task 1

K. INSPECTION

After the sewer section to be lined is thoroughly cleaned, inspection shall be made with a color pan and tilt, 360° rotating head camera specifically designed and constructed for sewer inspection. Lighting for the camera shall provide a clear picture of the entire periphery of the existing sewer. If the television inspection shows any areas where the sewer inside diameter may be deflected, decreased, or obstructed, the FDA will coordinate a point repair. The Contractor shall carefully inspect the interior of the pipeline to determine the location of any conditions that may prevent proper installation of the impregnated tube. These conditions may include protruding service taps, collapsed or crushed pipe, and reductions in the cross-sectional area of more than 40%.

The Contractor shall note these conditions so that they can be corrected. The original pipeline shall be cleared of these obstructions at the contracted unit price. Protruding taps or service connections which will obstruct or hinder the insertion of the liner, shall be removed to allow the liner to pass through. If inspection reveals an obstruction that cannot be removed by conventional sewer cleaning equipment, then a point repair excavation shall be recommended to remove or repair the obstruction. The FDA shall be notified immediately when the Contractor has determined the need for a point repair.

Upon completion of the liner installation the Contractor shall perform a television inspection to document the as-built condition. The Contractor shall provide two copies of as-built inspection to FDA in digital format for review and acceptance by the FDA.