33 01 99_Amendment 1.pdf

Crooked Creek Boat Ramp Road Erosion Repair

SECTION TABLE OF CONTENTS

DIVISION 33 - UTILITIES

SECTION 33 01 99

IN-PLACE CULVERT PIPE REHABILITATION [FOLDED/FORMED POLY VINYL CHLORIDE

(FFPVC) PIPE]

PART 1 GENERAL

1.1 REFERENCES TO ASTM STANDARDS

1.2 SYSTEM DESCRIPTION

1.2.1 Design Requirements

1.2.2 Performance Requirements

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Contractor Qualifications

1.4.2 Pre-Construction Conference and Performance Work Submittal

1.5 DELIVERY, STORAGE, AND HANDLING

1.6 SEQUENCING AND SCHEDULING

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 FFPVC Pipe All Applicable Manufacturer and Product Data

2.1.2 Proposed Non-Shrink Flowable Grout Mix Design

PART 3 EXECUTION

3.1 PREPARATION

3.1.1 Safety

3.1.2 Quality Control Plan

3.1.3 General CCTV Requirements

3.1.4 Pre-Construction Culvert Cleaning and Preparation

3.1.5 FFPVC Laboratory Test Results

3.1.6 Access to Culverts

3.1.7 Access to Water

3.1.8 Bypass Pumping

3.2 INSTALLATION

3.2.1 Insertion Procedure

3.2.2 Expansion Procedure

3.2.3 Cool Down Procedure

3.2.4 Structure Work

3.2.5 Reinstatement of Connections

3.3 WARRANTY

3.4 FFPVC Repair / Replacement

3.5 Record Drawings

3.6 Post-Installation Inspection

3.7 Final Acceptance

-- End of Section Table of Contents --

SECTION 33 01 99 Page 1 Certified Final Document - RTA W911WN21B8002 - Amendment 1

SECTION 33 01 99

IN-PLACE CULVERT PIPE REHABILITATION

[FOLDED/FORMED POLY VINYL CHLORIDE (FFPVC) PIPE]

PART 1 GENERAL

1.1 REFERENCES TO ASTM STANDARDS

Reference is made in this Specification to the latest editions of the following Specifications published by the following entities:

AMERICAN CONCRETE INSTITUTE (ACI)

ACI 304R (2000; R 2009) Guide for Measuring, Mixing, Transporting, and Placing Concrete

ACI 305R (2010) Guide to Hot Weather Concreting

ACI 306R (1988; R 2002) Cold Weather Concreting

ASTM INTERNATIONAL (ASTM) (ASTM)

ASTM C 150 (2007) Standard Specification for Portland Cement

ASTM C 157/157M (2008) Standard Test Method for Length Change of Hardened Hydraulic-Cement Mortar and Concrete

ASTM C 191 (2008) Standard Test Method for Time of Setting Hydraulic Cement by Vicant Needle

ASTM C 33/33M (2008) Standard Specification for Concrete Aggregates

ASTM C 827 (2001a; R 2005) Change in Height at Early Ages of Cylindrical Specimens from Cementitious Mixtures

ASTM C 94/94M (2009) Standard Specification for Ready-Mix Concrete

ASTM D 256 Test Method for Tensile Properties of Plastics

ASTM D 638 Standard Test Method for Tensile Properties of Plastics

ASTM D 790 Standard Test Methods for Flexural Properties of Un-reinforced and Reinforced Plastics and Electrical Insulating Materials

ASTM D 2122-98 (2004) Standard Test Method for Determining Dimensions of Thermoplastic Pipe and

SECTION 33 01 99 Page 2

Fittings

ASTM D 2152 Test Method for Adequacy of Fusion of Extruded Poly(Vinyl Chloride) (PVC) Pipe and Molded Fittings by Acetone Immersion

ASTM D 2412 Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading

ASTM D 2444 Test Method for Determination of the Impact Resistance of Thermoplastic Pipe and Fittings by Means of a Tup (Falling Weight)

ASTM F 1057 Practice for Estimating the Quality of Extruded Poly (Vinyl Chloride) (PVC) Pipe by the Heat Reversion Technique

ASTM F 1417 Test Method for Installation Acceptance of Plastic Gravity Sewer Lines Using Low-Pressure Air

ASTM F 1867 Standard practice for the Installation of Folded/Formed Poly (Vinyl Chloride) (PVC) Type A for Existing Sewer and Conduit Rehabilitation

1.2 SYSTEM DESCRIPTION

This section consists of the requirements and work needed to rehabilitate existing culverts by furnishing and installing pipe liners by the method of folded/formed PVC (FFPVC) lining. Use pipes and pipe liners of the sizes, types, design, and dimensions shown on the plans, and include all connections, joints, and other appurtenances as required to complete the work.

It is the intent of this section of the specification to provide for rehabilitating existing culverts without excavation by means of the installation of a folded/formed poly vinyl chloride (FFPVC) pipe, when installed, shall be continuous and tight-fitting throughout the entire length of the original pipe and have the capability to accommodate irregularities and varying diameter within the existing culvert pipe. The FFPVC shall extend the full length of the original pipe and provide a structurally sound, jointless and water-tight new pipe within a pipe. The FFPVC shall fit sufficiently tight within the existing pipe so as to not leak at any junctions, inlet/outlet structures, or pipe extensions. If leakage occurs through the wall of the pipe, the liner shall be repaired or removed as recommended by the FFPVC manufacturer. Final approval of the liner installation will be based on a leak tight pipe that meets all requirements of these Specifications.

The Contractor shall be responsible for furnishing all labor, supervision, materials, equipment, transportation and services necessary for traffic control, bypass pumping and/or diversion of flows, cleaning and television inspection of culverts to be lined, removal of obstructions, liner installation, culvert extensions, all quality controls, providing samples for performance of required material tests, final television inspection, testing of lined pipe system and warranty work in accordance with these

SECTION 33 01 99 Page 3

Specifications to furnish and install the FFPVC system.

The product furnished shall be a complete FFPVC system including all materials, applicable equipment, and installation procedures. All other in-place pipe repair systems or multi-component products will be required to meet the submittal requirements as contained herein. The Contractor shall submit the detailed information and anticipated installation work plan for the Contractor's proposed alternative lining system, which is subject to the review and approval by the Contracting Officer or their designated representative.

The FFPVC shall be continuous and jointless from access point to access point and shall be free of all defects that will affect the long term life and operation of the pipe.

Neither the FFPVC system, nor its installation, shall cause adverse effects to any of the Government’s processes or facilities. The use of the product shall not result in the formation or production of any detrimental compounds. The Contractor shall notify the Contracting Officer and identify any by-products produced as a result of the installation operations, test and monitor the levels, and comply with any and all local waste discharge requirements. The Contractor shall clean up, restore existing surface conditions and structures, and repair any of the FFPVC system determined to be defective by the Contracting Officer or designated representative.

The Contractor shall conduct installation operations and schedule cleanup in a manner to cause the least possible obstruction and inconvenience to traffic, pedestrians, recreationists, and property owners or tenants in the project area.

All sections of this Specification are mutually complimentary and the overall intent is that each Contractor shall provide for everything in his or her portion of the work required to make a complete and operable job in every respect unless specifically noted otherwise.

It is the intent of this Specification to ensure that the work, as completed, shall meet all applicable codes, ordinances, rules, and regulations of every authority having jurisdiction in the area where the construction is located. Failure of the Contractor to point out items that do not meet such requirements does not relieve any Contractor or his or her Subcontractors of the responsibility of meeting them.

1.2.1 Design Requirements

This section covers the minimum requirements for the rehabilitation of existing culverts by the installation of FFPVC, including type of repair, method of repair, materials, and documentation and testing requirements for each line scheduled for rehabilitation as indicated in the contract drawings.

The scope of work in this Contract includes, but is not limited to:

a. Development and submission of all required plans, material, and process submittals.

b. Cleaning of and removal of obstructions in designated culverts.

c. Post-Cleaning CCTV inspection and video taping of the

SECTION 33 01 99 Page 4 designated culverts.

d. Point grouting in designated sections to be determined in the field after review of Post-Cleaning CCTV video.

e. Insertion of a FFPVC liner into designated pipe sections, heating, expanding, and cooling of the liner.

f. Materials testing by Contractor via independent laboratory.

g. Internal reestablishment of lateral connections, if applicable.

h. Post-Construction CCTV inspection of completed repair sections.

i. Repair or replacement of identified defects.

j. Site restoration.

1.2.2 Performance Requirements

Notify the Contracting Officer or designated representative 24 hours in advance of tests and perform tests at the work site if practicable.

Conform to local, state, and federal requirements.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Certification of compliance with these Specifications; G

The Contractor shall submit, prior to installation of the lining materials, certification of compliance with these Specifications. Certified material test results shall be included that confirm that all materials conform to these Specifications. Materials not complying with these requirements will be rejected.

Written Report for proposed technology and execution of lining operations; G, DO

Submit a written report including a complete description of the proposed technology and outlining the step-by-step procedures for the execution of the lining operations (i.e. length, line, obstructions, excavation, cleaning & CCTV, grouting, lining etc.) prior to the commencement of work. Any deviation from the pre-specified plan for the relining operation must be presented to the Contracting Officer or designated representative prior to execution.

Written Schedule for Culvert Lining Times; G, RO

SECTION 33 01 99 Page 5

Provide a written schedule for culvert lining times for each pipe. Provide the schedule for each delivery order no less than 15 calendar days prior to beginning work.

Written method for monitoring liner forming and cooling temperatures; G, DO

Submit a written method for monitoring liner forming and cooling temperatures for approval no less than 15 calendar days prior to beginning work.

Detailed instructions for making future connections; G, DO

The Contractor shall provide the Contracting Officer or designated representative with detailed instructions for making future connections to the reconstructed pipeline.

Performance Work Statement (PWS); G, DO

The Contractor shall submit a Performance of Work Submittal (PWS) as detailed in Section 1.4.2 below.

Quality Control Plan; G, DO

Contractor Qualifications; G, DO

Culvert CCTV Inspection Videos, Electronic Copies; G, DO

SD-03 Product Data

FFPVC Pipe all applicable manufacturer and product data; G

The Contractor shall submit FFPVC data including the Manufacturer and description of product components, all MSDS sheets, Manufacturer Literature and Data, including physical characteristics, application and installation instructions, shipping, storage and handling instructions and recommendations for all materials to be furnished for the project.

Proposed Non-Shrink Flowable Grout Mix Design; G, DO

Proposed non-shrink flowable grout mix design to be used for point grout repair and void filling prior to lining operations. Polymeric grouts may be proposed by the Contractor but will be subject to additional review and will require specific written approval by the Contracting Officer.

SD-05 Design Data, G

Design Calculations; G, DO

The Contractor shall submit design calculations demonstrating that the minimum properties and strength requirements are met or exceeded and that the proposed liner product and proposed liner thickness is adequate based on field conditions (i.e., burial depth and anticipated vehicular loading).

Record Drawings; G, DO

SD-06 Test Reports, G

FFPVC Laboratory Test Results; G, DO

SECTION 33 01 99 Page 6

1.4 QUALITY ASSURANCE

1.4.1 Contractor Qualifications

Qualifications of Contractor: Installation of the culvert lining system shall be performed by an experienced Contractor fully licensed by the Process Manufacturer. The Contractor shall provide evidence of lining experience. The Contractor shall have a minimum of three years of continuous experience installing FFPVC liners in pipe of a similar size, length and configuration as contained in this contract. The lead personnel including the superintendent, the foreman and the lead crew personnel for the CCTV inspection, the FFPVC liner installation, must have a minimum of three years of total experience with pipe lining and FFPVC technology proposed for this contract and must have demonstrated competency and experience to perform the scope of work contained herein. The name and experience of each lead individual performing work on this contract shall be submitted during the submittal process for approval by the Contracting Officer or designated representative.

1.4.2 Pre-Construction Conference and Performance Work Submittal

The Contractor shall submit, to the Contracting Officer, a Performance Work Statement (PWS) at the pre-construction meeting, which clearly defines the FFPVC product delivery in conformance with the requirements of these contract documents. Unless otherwise directed by the Contracting Officer or designated representative, the PWS shall at a minimum contain the following:

a. Clearly indicate that the FFPVC will conform to the project requirements as indicated in these Specifications.

b. All applicable installation data as it relates to the method of installation and number of years experience of their installation crew.

c. The project installation list of all past projects installed in the respective state.

d. Third party technical test results covering all aspects of the product to include, but not be limited to, structural integrity and product life cycle.

Where the scope of work is specifically delineated in the contract documents, a detailed installation plan shall be developed and included in the Performance Work Statement (PWS) describing all preparation work, cleaning operations, pre-CCTV inspections, by-pass pumping, traffic control, point grouting repair, liner installation procedure, method of heating/cooling, culvert extension and junction connection, quality control, testing to be performed, final CCTV inspection, warrantees furnished and all else necessary and appropriate for a complete FFPVC liner installation. The detailed installation schedule conforms to in all respects to the requirements of these technical specifications.

Performance Work Statement (PWS) shall include the Contractor’s description of the proposed FFPVC lining technology, including a detailed plan for execution of the proposed lining activities.

Performance Work Statement (PWS) shall contain a description of the FFPVC materials to be furnished for the project, and certification of compliance

SECTION 33 01 99 Page 7 with these Specifications.

a. Certified material results shall be included that all materials conform to these Specifications and/or the pre-approved system.

Materials not complying with these requirements will be rejected.

b. Included in the submittals shall be a certified original copy with supporting literature from the FFPVC supplier/manufacturer of the PVC material properties to assess compliance with these Specifications.

The FFPVC shall be designed in accordance with ASTM F1867 standards as a liner to rehabilitate the existing pipe (partially deteriorated) or as a fully structural stand-alone pipe-within-a-pipe (fully deteriorated) based on the results of pre-lining CCTV inspection. The installed FFPVC shall meet or exceed all contract specified physical properties and fit tightly within the existing pipe all within the tolerances specified. The installed FFPVC shall withstand all applicable surcharge loads (soil overburden, live loads, etc.) and external hydrostatic (groundwater) pressure, if present, for each specific installation location. The FFPVC design shall assume no bonding to the original pipe wall. The contractor shall provide Engineering design calculations, in accordance with the Appendix of ASTM F 1867, for each length of liner to be installed including the required structural wall thickness of each proposed FFPVC section. It will be acceptable for the Contractor to submit a design for the most severe line condition and apply that design to all of the line sections. These calculations shall be performed and certified by a Professional Engineer with current registration in the State of Pennsylvania. All calculations shall include data that conforms to the requirements of these Specifications. The following design parameters are to be applied for this project:

a. Design Safety Factor = 2.0 for pipes less than 36” in diameter.

b. Minimum Design Ovality = 2%. Ovality as defined by

ASTM F 1867.

c. Constrained Soil Modulus Per AASHTO LRFD Section 12,AWWA Manual M45, and/or ASCE Journal of Transpiration Engineering (Jan/Feb 2004). No value less then 1,000 PSI shall be used.

d. Groundwater Depth = Assume hydrostatic loading based on a groundwater level that is two (2) feet above the crown of the subject culvert.

e. Soil Depth Above the Crown of the Pipe = As indicated on the Plans.

f. AASHTO H20 live loadings shall be used for all lined sections under roadways.

g. Soil Load (assumed) = 120 lb/cu. Ft.

h. Minimum Service Life = 50 years

Technology data of proposed Manufacturer(s) shall be submitted for all FFPVC products and all associated technologies to be furnished.

SECTION 33 01 99 Page 8

Submittals shall include information on the FFPVC pipe intended for installation and all tools and equipment required for a complete installation. The PWS shall identify which tools and equipment will be redundant on the job site in the event of equipment breakdown. All equipment, to be furnished for the project, including proposed back-up equipment, shall be clearly described. The Contractor shall outline the mitigation procedure to be implemented in the event of key equipment failure during the installation process.

The Performance Work Statement (PWS) shall include a detailed description of the Contractor’s proposed procedures for removal of any existing lockages in the pipeline that may be encountered during the cleaning process.

Compensation for all work required for the submittal of the PWS shall be included in and considered incidental to the various pipelining items contained herein.

1.5 DELIVERY, STORAGE, AND HANDLING

All materials, shipped to the project site, shall be accompanied by test reports certifying that the material conforms to the ASTM standards listed herein. Materials shall be shipped, stored, and handled in a manner consistent with written recommendations of the FFPVC system Manufacturer to avoid damage.

Damage includes, but is not limited to, gouging, abrasion, deformation, cutting, puncturing, tearing, or ultra-violet (UV) degradation. etc.

All damaged materials shall be promptly removed from the project site and disposed of in accordance with all current applicable agency regulations at the Contractor’s expense.

The entire length of each FFPVC liner shall be heated and coiled onto a reel in a continuous length and transported to the site prior to insertion in accordance with the Manufacturer’s recommendations.

All on-site storage locations shall be approved by the Contracting Officer or designated representative.

1.6 SEQUENCING AND SCHEDULING

Submit plan for final approval of construction sequence and schedule prior to commencing construction.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 FFPVC Pipe All Applicable Manufacturer and Product Data

General: The liner shall be fabricated from materials which will be chemically resistant to withstand external exposure to soil bacteria and any chemical attack which may be due to materials in the surrounding ground.

Design Life: The installed FFPVC shall have a long term (50 year) corrosion resistance to the typical constituents found in stormwater runoff.

SECTION 33 01 99 Page 9

Liner Thickness: The nominal liner wall thickness shall be constructed, as a minimum, to the nearest 0.5 mm increment, rounded up from the design thickness for that section of installed FFPVC. The liner content shall be determined by the Contractor to ensure a cured thickness of liner, as determined by the Contractor and approved by the Contracting Officer for each culvert section. Thickness of cured liner to be as specified (+10 percent; -5 percent).

FFPVC Physical Material Properties: used in the lining process shall provide the minimum mechanical properties listed below.

1. Impact Strength: 0.65ft-lb/in of notch

2. Tensile Strength: 4,500 psi

3. Tensile Modulus: 360,000 psi

4. Flexural Strength:7,500 psi

5. Flexural Modulus: 360,000 psi

Pipe Stiffness Properties: shall be in accordance with the following table.

Liner Pipe O.D. (nominal), inches

Dimension Ratio Pipe Stiffness (pii)

4 35 31

6 35 31

8 35 31

10 35 31

12 35 31

15 35 - 50 47 - 13

18 35 - 60 37 - 7

21 42 - 70 22 - 5

24 48 - 80 15 - 4

30 60 - 100 7 - 2

36 72 - 120 5 - 1

Pipe Extrusion Quality: shall be evaluated by the acetone immersion test and shall not flake or disintegrate when tested in accordance with ASTM D2152 and by the heat reversion method in accordance with ASTM F1057.

Impact Resistance: Determine the impact resistance of the rounded pipe in accordance with the applicable section of ASTM D2444, using a 20-lb Tup A and the flat plate Holder B. Test three specimens. All shall pass. If one fails, test another six specimens; eleven passes out of twelve tested shall be

SECTION 33 01 99 Page 10 acceptable.

All materials shall be approved by the Contracting Officer or designated representative prior to the insertion into the existing culvert.

Rejected material shall be replaced with approved materials at the Contractor's expense.

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

The minimum length of the FFPVC liner shall be that deemed necessary by the installer to effectively span the distance from the inlet structure to the culvert outlet or access point plus the amount required to run-in and run-out for the installation process and prove for testing samples.

Pipe in compliance with this specification shall be clearly marked at intervals of 5 ft or less as follows:

1. Manufacturer’s name or trademark and code,

2. Nominal outside diameter,

3. The legend “DR XX Folded PVC Pipe,”

4. Production date code

2.1.2 Proposed Non-Shrink Flowable Grout Mix Design

All grout utilized shall be durable, non-staining, non-shrink, nonmetallic grout. The grout shall show no shrinkage in accordance with ASTM C-827 prior to initial setting and shall show no shrinkage in the hardened state under ASTM C-157, “Test Method for Length Change of Hardened Hydraulic-Cement mortar and Concrete,” Corps of Engineers Specification CRD-C-588 and the field cylinder test. The grout shall conform to ASTM-C-191, “Test Method for Time of Setting of Hydraulic Cement by Vicat Needle,” concerning time of initial set. All grouting operations shall be completed in accordance with the recommendations of ACI, CSI, and the manufacturer's published specifications for mixing and placing.

The minimum allowable compressive strength on samples taken from the transportation unit at the point of discharge shall be 800 psi in 28 calendar days. The required slump shall be 7 inches or as required to successfully fill voids and restore the approximate invert of the host pipe and as approved by the Contracting Officer or designated representative.

Any polymeric grouts proposed by the Contractor will be subject to review and written approval by the Contracting Officer or designated representative prior to use on the project.

PART 3 EXECUTION

3.1 PREPARATION

Complete the following preparations, unless approved otherwise by the Contracting Officer or designated representative. The Contracting Officer makes no guarantee regarding the information, data, and physical condition

SECTION 33 01 99 Page 11 of underground facilities or existing culvert pipes. Before commencing with any work, or ordering any materials, physically measure and perform

CCTV

inspection of the existing culvert pipes to verify that the rehabilitation specified herein is appropriate.

3.1.1 Safety

The Contractor shall carry out his or her operations in strict accordance with all OSHA, Manufacturer, and other pertinent regulatory agency safety requirements.

Any work within manholes or conduits shall be classified as “Confined Space” and will require complete compliance with OSHA Standards. The Government will not be liable for any citations or fines received by the contractor. The Contractor shall be fully responsible for adhering to all confined space entry requirements.

The Contractor shall secure the site for the working conditions in compliance with all OSHA, Manufacturer, and other pertinent regulatory agency requirements. The Contractor shall erect such signs and other devices as are necessary for the safety of the work site.

The Contractor shall submit a proposed Safety Plan to the Contracting Officer, prior to beginning any work, identifying all competent persons.

The plan shall include a description of a daily safety program for the job site and all emergency procedures to be implemented in the event of a safety incident. All work shall be conducted in accordance with the Contractor’s submitted Safety Plan.

Compensation for all work required for the submittal of the Safety Plan shall be included and considered incidental to the various pipelining items contained in the Proposal.

3.1.2 Quality Control Plan

A detailed quality control plan (QCP) shall be submitted to the Contracting Officer that fully represents and conforms to the requirements of these Specifications. At a minimum the QCP shall include the following:

A detailed report of the proposed quality controls to be performed by the Contractor.

Defined responsibilities, of the Contractor’s personnel, for assuring that all quality requirements, for this contract, are met. These shall be assigned, by the Contractor, to specific personnel. Said personnel shall be identified within the QCP.

Proposed procedures for quality control, product sampling and testing shall be defined and submitted as part of the plan.

Proposed methods for product performance controls, including method of and frequency of product sampling and testing both in raw material form and cured product form.

A scheduled performance and product test results review between the Contractor and the Contracting Officer or designated representative at a regularly scheduled job meeting.

SECTION 33 01 99 Page 12

Inspection forms and guidelines for quality control inspections shall be prepared in accordance with the standards specified in this contract and submitted with the QCP.

Compensation for all work required for the submittal of the QCP shall be included in the various pipelining items contained in the Proposal.

3.1.3 General CCTV Requirements

CCTV inspection of culverts shall be performed by experienced personnel trained in locating breaks, obstacles, and service connections by closed circuit television. Only PACP certified personnel trained in locating breaks, obstacles, and service connections by closed circuit television shall perform the inspection.

The CCTV equipment used shall consist of complete closed circuit color television system including a camera, lighting, electronic footage counter, television monitor, mobile television studio, video/DVD recorder/player with appropriate recording media for recording televising operations.

The television camera used for the inspection shall be pan and tilt type color camera, which is specifically designed and constructed for such inspection and shall have above ground control for forward and backward movement in the culvert. Lighting for the camera shall be waterproof and suitable to allow a clear picture of the entire periphery of the pipe. The camera shall be operative under 100 percent humidity conditions. The camera, television monitor and other components of the video system shall be capable of producing picture quality to the satisfaction of the Contracting Officer or designated representative; and, if unsatisfactory, equipment shall be removed and no payment will be made for any unsatisfactory inspection. An electronic footage counter shall be set up to accurately measure the exact distance of the camera from the centerline of the starting inlet/outlet. This measurement shall be displayed on the monitor and recorded at all times. The importance of accurate distance measurements is emphasized.

While recording, the camera shall be moved through the line at a moderate rate, stopping when necessary to permit the proper documentation of the culvert condition. In no case will the television camera be moved at a speed greater than 30 feet per minute.

The purpose of video recordings shall be to supply a visual and audio record of all line segments that are televised. Video recording playback shall be at the same speed that it was recorded. The contractor shall have all recordings and necessary playback equipment readily accessible for review by the Contracting Officer or designated representative during the project.

All recorded inspection video shall be provided in DVD and/or MPEG format.

VHS video tapes are not acceptable. All inspection logs shall utilize a database system such as WinCan or Approved Equal.

3.1.4 Pre-Construction Culvert Cleaning and Preparation

Prior to installation of the FFPVC liner the Contractor shall prepare the interior of the existing host pipe by thoroughly cleaning all debris and removing all obstructions that will effect the installation and the final FFPVC product delivery in accordance with the requirements of these

SECTION 33 01 99 Page 13 technical specifications.

Cleaning shall include the trapping, removal and disposal of all foreign material including but not limited to, dirt, gravel, rocks, sand, roots, sediments, deteriorated portions of the host pipe protruding into the culvert cross section or other debris from the host pipe.

The Contractor shall utilize adequate, high velocity hydrocleaning equipment specifically designed for the cleaning of sewers. Should hydrocleaning not prove adequate, other approved mechanical cleaning or cutting equipment shall be utilized as necessary.

The Contractor shall clean debris out of the pipe in accordance with the latest edition of the National Association of Sewer Service Companies (NASSCO) Specifications. Definitions of light, medium, and heavy pipe cleaning follow:

a. Light Cleaning: Where it has been determined through a visual inspection that only small deposits of loose debris exist within the pipeline.

b. Medium Cleaning: Where it has been determined through a visual inspection that medium deposits of loose debris exist within the pipeline.

c. Heavy Cleaning: Where it has been determined through a visual inspection that heavy deposits of loose debris or root growth exist within the pipeline. Heavy equipment will be used to facilitate the removal of heavy deposits.

The Contractor is responsible for clearing the culverts of obstructions such as solids, dropped joints, protruding portions of deteriorated host pipe, or collapsed pipe that will prevent the insertion of the liner. It shall be the responsibility of the Contractor to clear the line of obstructions or collapsed pipe that will prevent the insertion of the liner. If inspection reveals an obstruction, misalignment, broken or collapsed section or sag that cannot be removed without excavation then the Contractor shall immediately notify the Contracting Officer or designated representative to discuss alternatives. Any alternative shall be approved in writing by the Contracting Officer prior to the commencement of the work.

Please note that the pipe cleaning procedures and methods specified herein shall also be applicable to cleaning of other existing stormwater conveyance pipes on-site as noted on the contract drawings.

The contractor is responsible for clearing the host pipe of conditions and/or obstruction that will prevent the installation of the FFPVC liner.

The Contractor shall perform point repair grouting where preconstruction CCTV inspections reveal severely deteriorated or collapsed pipe, and/or sags, that will prevent the installation of the FFPVC liner. Any such point repairs shall be approved in writing by the Contracting Officer prior to the commencement of the work.

Placing of the point repair grout shall be done in accordance with ACI (American Concrete Institute) Standard 304, of latest revision, Recommended Practice for Measuring, Mixing, and Placing Concrete and all applicable portions of said standards shall apply. In general, the grout will need to be delivered to the point repairs via tremie tube/pipe and pumping methods.

SECTION 33 01 99 Page 14

The Contractor shall take all necessary precautions to ensure that grout placed during hot or cold weather is not damaged by the extremities of temperature. To this end, the Contractor shall place the grout in accordance with the applicable portions of ACI Standard No’s. 305 and 306. No grout will be accepted which is frozen or damaged due to extremes in weather.

The Contractor is responsible for the sealing of areas of significant infiltration as directed by the Contracting Officer or designated representative at the time of Post-Cleaning CCTV Inspection.

Precautions shall be taken by the Contractor during hydraulic cleaning to ensure that water does not flood property in connection with the culvert section being cleaned. Any damage caused during the cleaning process shall be repaired at the expense of the Contractor.

Precautions must also be taken to ensure that the culverts are not damaged by improper use of the cleaning equipment. Any damage caused during the cleaning process shall be repaired at the expense of the Contractor.

The Contractor shall dispose off all debris at no charge.

3.1.5 FFPVC Laboratory Test Results

All materials furnished, as part of this contract shall be marked with detailed product information, stored in a manner specified by the manufacturer, and tested to the requirements of these technical specifications.

Tests for compliance with this specification shall be made as specified herein and according to the applicable ASTM specification. A certificate of compliance with this specification shall be furnished by the Manufacturer for all material furnished under this specification.

The physical properties of the installed FFPVC shall be verified through field sampling and laboratory testing. All materials and test results shall be furnished by the Contractor to the Contracting Officer or designated representative for review and ultimate approval. All materials testing shall be performed at the Contractor’s expense, by an independent third party laboratory selected by the Contractor as recommended by the FFPVC Manufacturer. All tests shall be in accordance with applicable ASTM test methods to confirm compliance with the requirements specified in these contract documents.

On pipes greater in diameter than is practical to produce restrained samples, the Contracting Officer may at his or her discretion, require plate samples or designate a location in the newly installed FFPVC where the Contractor shall take a sample (i.e., from the excess material trimmed from the inlet/outlet of the host pipe). The Opening produced from the sample shall be repaired in accordance with Manufacturers recommended procedures.

The laboratory results shall identify the test sample location as referenced to the nearest manhole and station. Final payment for the project shall be withheld pending receipt and approval of the test results. If properties tested do not meet minimum requirements or any defects are found, the FFPVC shall be repaired or replaced by the Contractor, at no additional cost to the Government.

SECTION 33 01 99 Page 15

Chemical resistance - The FFPVC system installed shall meet the chemical resistance requirements of ASTM standards.

All costs associated with providing FFPVC samples for testing shall be incidental to the installation of the FFPVC liner and be the responsibility of the Contractor.

Payment for all laboratory testing shall also be the responsibility of the Contractor and be considered incidental to performance of the work specified herein.

3.1.6 Access to Culverts

The Contractor may, under the direction of the Contracting Officer, utilize both the upstream inlet and downstream outlet of the existing culverts to be lined. If traffic must be restricted for satisfactory performance of the work , the Contractor shall furnish a detailed traffic control plan and all labor and equipment necessary or implementation of the plan. The plan shall be in conformance with the requirements of the local agency having jurisdiction over traffic control and shall be subject to review by the Contracting Officer or designated representative prior to implementation.

If encroachment onto private property is required, the Government shall be responsible for obtaining the required access permissions.

3.1.7 Access to Water

The Contractor shall be responsible for securing access to his or her own water supply.

3.1.8 Bypass Pumping

If required, provide for continuous bypass flow around the section or sections of pipe designated for the liner process. Provide pump and bypass lines of adequate size and capacity to handle the necessary flow.

Bypass pumping and all associated costs shall be incidental to the installation of the FFPVC liner.

3.2 INSTALLATION

3.2.1 Insertion Procedure

The FFPVC Liner shall be installed per the Manufacturer’s Specifications as described and submitted in the PWS.

The spool of folded pipe shall be positioned near the insertion point and contained in a heating chamber. Maintain the specified temperature in the heating chamber for the specified minimum duration in accordance with the Manufacturer’s specifications before inserting the folded liner into the host pipe.

A cable shall be strung through the existing host pipe and attached to the folded pipe. The folded pipe shall be heated along the entire length and fed through the insertion point. The pipe is pulled, with a power winch unit and the cable, through the existing pipe to the termination point.

Maintain the upstream feed with the pipe reel to avoid stretching the pipe material with the winch cable. Pulling forces shall be monitored so as not

SECTION 33 01 99 Page 16 to exceed the axial strain limits of the folded pipe material. Pull enough liner material to allow for insertion of a flowthrough plug at the termination point.

After insertion is complete, cycle down the steam temperature to allow the liner to relax and reduce tensile stress on the material. During the relaxation cycle, the ends of the liner will tend to contract. It may take several heating/cooling cycles until the liner has relaxed and is no longer contracting.

3.2.2 Expansion Procedure

Expansion shall be accomplished by utilizing the appropriate medium in accordance with the Manufacturer’s recommended installation procedure. The heating/cooling temperatures shall be monitored and logged during the heating/cooling cycles. The Manufacturer’s recommended heating, expansion, and cooling schedule shall be used for each line segment installed, and the liner wall thickness and the existing ground conditions with regard to temperature, moisture level, and thermal conductivity of soil, per ASTM as applicable, shall be taken into account by the Contractor.

To check that adequate temperatures are being achieved prior to expansion, suitable monitors to gage temperature shall be placed at the insertion and termination ends.

Insert flow-through plugs into ends of folded pipe. Ensure plugs are adequately restrained.

Through the use of heat and pressure, the folded pipe shall be expanded fully. Expansion pressures shall be sufficient to unfold the PVC pipe, press it against the wall of the existing conduit, and form dimples at service connections. Folded pipe expansion pressures typically are in the range of 0.25 to 3 psi, depending on liner size, or other site conditions.

The Contractor shall keep and provide to the Contracting Officer or designated representative written records/logs of, heat source incoming and outgoing temperatures, and temperatures at remote sensor locations.

3.2.3 Cool Down Procedure

The Contractor shall cool the FFPVC in accordance with the approved FFPVC Manufacturer’s instructions.

Temperatures and curing data shall be monitored and recorded, by the Contractor, throughout the installation process to ensure that each phase of the process is achieved as approved in accordance with the FFPVC System Manufacturer’s specification.

After the formed pipe has cooled down, the terminating ends shall be trimmed to a minimum of 2 in. beyond the existing pipe.

3.2.4 Structure Work

After the cool down process has been completed, seals consisting of a resin mixture or hydrophilic seal compatible with the installed FFPVC shall be applied at inlet/outlet structure walls in accordance with the FFPVC System Manufacturer’s recommendations.

SECTION 33 01 99 Page 17

3.2.5 Reinstatement of Connections

After the liner has been fully installed and cooled it shall be the Contractor’s responsibility to reconnect all existing active services. The reconnection of services shall be performed without excavation, unless otherwise directed by the Contracting Officer, from the interior of the pipeline by means of a television camera directed cutting device. Location of the service shall be from the pre-inspection records and camera observation.

All existing and confirmed active service connections and any other service laterals to be reinstated as directed by the Contracting Officer or designated representative shall be reopened robotically to their original shape and to 95% of their original capacity. The edges of the opening shall not have pipe fragments or liner fragments, which may obstruct flow or snag debris. No additional compensation will be paid for the repair of over-cut service connections.

No separate compensation shall be made for reinstatement of existing connections. All work necessary to satisfactorily reinstate connections to the lined pipe shall be considered incidental to completion of the work specified herein and shall include all materials, labor, equipment and supplies necessary to complete the work as required in these Specifications.

3.3 WARRANTY

The Contractor shall warrant all workmanship and materials to be free of defects for a period of two years from date of final payment.

During the Contractor warranty period any defect, which may affect the integrity, strength, function and/or operation of the pipe, shall be repaired at the Contractor’s expense.

After a pipe section has been lined and for a period of time up to two years following completion of the project, the Government may inspect all or portions of the lined system. The specific locations will be selected at random by the Government and will include all sizes of FFPVC from this project. If it is found that any of the FFPVC has developed abnormalities since the time of "Post Construction Television Inspection," the abnormalities shall be repaired and/or replaced as defined in the Section entitled “FFPVC Repair/Replacement”. If, after inspection of a portion of the lined system under the contract, problems are found, the Government may televise all the FFPVC installed on the contract. All verified defects shall be repaired and/or replaced by the Contractor and shall be performed in accordance with the Section entitled “FFPVC Repair/Replacement”, and as per the original Specifications, all at no additional cost to the Government.

3.4 FFPVC Repair / Replacement

Occasionally a FFPVC installation will require repair or replacement of a defective section. The Contractor shall outline specific repair or replacement procedures for potential defects that may occur in the installed FFPVC. Repair/replacement procedures shall be as recommended by the FFPVC system Manufacturer and shall be submitted as part of the PWS.

Defects in the installed FFPVC that will not affect the operation and

SECTION 33 01 99 Page 18 long-term life of the product shall be identified and defined.

Repairable defects that may occur in the installed FFPVC shall be specifically defined by the Contractor based on Manufacturer’s recommendations, including a detailed step-by-step repair procedure, resulting in a finished product meeting the requirements of these contract Specifications.

Un-repairable defects that may occur to the FFPVC shall be clearly defined by the Contractor based on the Manufacturer’s recommendations, including a recommended procedure for the removal and replacement of the FFPVC.

During the Contractor warranty period any defect, which may affect the integrity, strength, function and/or operation of the pipe, shall be repaired at the Contractor’s expense..

3.5 Record Drawings

Record drawings, pre & post inspection videotapes and/or CD/DVD’s shall be submitted to the Contracting Officer, by the Contractor within two weeks of final acceptance of said work or as specified by the Contracting Officer. Record drawings will include the identification of the work completed by the Contractor and shall be prepared on one set of Contract Drawings provided to the Contractor at the onset of the project.

Record drawings shall be kept on the project site at all times, shall include all necessary information as outlined in the PWS and shall be updated as the work is being completed, and shall be clearly legible.

Compensation for all work required for the submittal and approval of Record Drawings shall be considered incidental to completion of the culvert repair work specified herein.

3.6 Post-Installation Inspection

After completion of the liner installation and processing, service opening and grouting, a Post-Installation CCTV inspection shall be completed by the Contractor.

The Contractor shall perform a detailed closed-circuit television inspection in accordance with PACP standards, in the presence of the Contracting Officer or designated representative after installation of the FFPVC liner and reinstatement of any connections.

A radial view (pan and tilt) TV camera shall be used. The camera shall be panned 360 degrees around the circumference of the pipe and along the wall of the finished pipe at 10-foot intervals. Unedited digital documentation of the inspection shall be provided to the Contracting Officer within ten working days of the liner installation. The data shall note the inspection date, location of all reconnected side sewers, debris, as well as any other defects in the liner, including, but not limited to, creases, folds, wrinkles, gouges, cracks, bumps, or bulges.

If post installation inspection documentation is not submitted within ten working days of the liner installation, the Contracting Officer may at its discretion suspend any further installation of FFPVC until the post-installation documentation is submitted. As a result of this suspension, no additional working days will be added to the contract, nor will any adjustment be made for increase in cost. Immediately prior to

SECTION 33 01 99 Page 19 conducting the closed circuit television inspection, the Contractor shall thoroughly clean the newly installed liner removing all debris and buildup that may have accumulated.

3.7 Final Acceptance

Before final acceptance all FFPVC sample testing and all applicable repairs to the FFPVC liner shall meet the requirements of these Specifications.

The installed FFPVC shall be continuous over the entire length of a sewer line section and be free from damage, visual defects such as foreign inclusions, dry spots, pinholes, major wrinkles, folds, creases, and/or de-laminations.

The inner surface shall be free of wrinkles. pleats, folds, creases, or similar imperfections. Some minor waviness that will not appreciably decrease the flow cross-section or affect the flow characteristics or be the cause of a possible blockage may be permitted if approved by the Contracting Officer or designated representative.

Wrinkles, pleats, folds, creases or similar which are perpendicular to the flow or greater than ½” in depth shall be repaired at the Contractor’s expense.

Any defect, which will or could affect the structural integrity or strength of the linings, shall be repaired at the Contractor’s expense.

The lining shall be impervious and free of any leakage from the pipe to the surrounding ground or from the ground to inside the lined pipe. Where leakage is observed through the wall of the pipe, the contractor shall institute additional testing including but not limited to air testing, localized testing and any other testing that will verify the leak-proof integrity of the installed FFPVC to the satisfaction of the Contracting Officer or designated representative. If the wall of the FFPVC leaks, it shall be repaired or removed and replaced with a watertight pipe as recommended by the manufacture of the FFPVC system.

If any of the connections leak water between the host pipe and the installed liner, the connection mainline interface shall be sealed to provide a watertight connection.

The beginning and end of the FFPVC shall be sealed to the existing host pipe in accordance with the…