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    SECTION 02920

    PVC SHEET LINER FOR CONCRETE SANITARY SEWERS

   PART 1 - GENERAL

   1.01 SECTION INCLUDES

    Supply and installation of a PVC sheet liner in reinforced concrete pipe. To accomplish this, the liner must be continuous and free of pinholes both across the joints and in the liner itself.

    All work in connection with the installation of the lining in concrete pipe and the field sealing and welding of joints, shall be done in strict conformance with all applicable specifications, instructions, and recommendations of the lining manufacturer.

    The manufacturer of the lining shall furnish an affidavit attesting to the successful use of its material for a minimum period of 10 years in sewage conditions recognized as corrosive or otherwise detrimental to concrete.

   1.02 SUBMITTALS

    A. Technical data on the liner, including standard catalogue information.

    B. Installation instructions.

    C. All structural design submitted shall be sealed by Professional Engineer registered in the State of Tennessee.

   PART 2 - PRODUCT

   2.01 MATERIAL

    A. Liner shall be Ameron T-Lock as manufactured by Ameron Protective Coatings Division, Brea, California, or approved equal.

    B. Composition: The material used in the liner and in all joint, corner, and welding strips shall be a combination of poly (vinyl chloride) resin, pigments, and plasticizers specially compounded to remain flexible. Poly (vinyl chloride) resin shall constitute not less than 99 percent, by weight, of the resin used in the formulation. Copolymer resins will not be permitted.

    C. The installed liner shall be capable of withstanding a minimum of 40 feet of external hydrostatic head.

   2.02 PHYSICAL PROPERTIES

    A. All plastic liner plate sheets, joint, corner, and welding strips shall have the following physical properties when tested at + 77oF.

    Property Initial 112-Day Chemical Test

    Tensile Strength 2,200 psi min. 2,100 psi min.

    Elongation at Break 200% min. 200 min.

    Shore durometer Sec. 50-60 + with respect to

    Type D-10 sec. 35-50 + initial test result

    Weight Change + 1.5 percent

    B. Tensile specimens shall be prepared and tested in accordance with ASTM D412 using die B. Weight change specimens shall be 1-inch by 3-inch sample of the sheet thickness. Specimens may be taken from sheet and strip at any time prior to final acceptance of work.

    C. Liner plate locking extensions embedded in concrete shall withstand a test pull of at least 100 pounds per linear inch, applied perpendicular to the concrete surface for a period of one minute, without rupture of the locking extensions or withdrawal from embedment. This test shall be made at a temperature of 70oF to 80oF inclusive.

    D. All plastic liner plate sheets (including locking extensions) and all joint, corner, and welding strips shall be free of cracks, cleavages, or other defects adversely affecting the protective characteristics of the material. The Engineer may authorize the repair of such defects by approved methods.

    E. The lining shall have good impact resistance, shall be flexible, and shall have an elongation sufficient to bridge up to 1/4-inch settling cracks which may occur in the pipe or in the joint after installation without damage to the lining.

    F. The lining shall be repairable at any time during the life of the pipe or structure.

   2.03 CHEMICAL RESISTANCE

    A. After conditioning to constant weight at 100oF, tensile specimens and weight change specimens shall be exposed to the following solutions for a period of 112 days at 77oF +5o.

    B. At 30-day intervals, tensile specimens and weights change specimens shall be removed from each of the chemical solutions and tested in accordance with paragraph 2.2 B. above. If any specimen fails to meet the 112-day requirements before completion of the 112-day exposure, the material will be subject to rejection.

    C. Chemical Solution Concentration

    Sulfuric acid 20 percent *

    Sodium hydroxide 5 percent

    Ammonium hydroxide 5 percent *

    Nitric acid 1 percent *

    Ferric chloride 1 percent

    Soap 0.1 percent

    Detergent (liner alkyl benzyl

    sulfonate or LAS) 0.1 percent

    Bacteriological BOD not less than 700 ppm

    * Volumetric percentages of concentrated C.P. grade reagents.

   2.04 DETAILS AND DIMENSIONS OF BASIC SIZE SHEETS

    Liner sheets shall be a minimum of 0.065 inch in thickness. Locking extensions (T-shaped) must be of the same material as that of the liner and shall be integrally extruded with the sheet. Locking extensions shall be approximately 2.5 inches apart and shall be at least 0.375 inch high.

   2.05 PIPE-SIZE SHEETS

    A. Pipe linings shall be supplied as pipe-size sheets, fabricated by shop-welding the basic-size sheets together. Shop welds shall be made by lapping sheets a minimum of 1/2-inch and apply heat and pressure to the lap to produce a continuous welded joint. Tensile strength measured across shop-welded joint measured in accordance with ASTM D412 shall be at least 2,000 psi.

    B. Sheets shall have transverse strap channels cut in the locking extensions so that strap can be placed into and perpendicular to the locking extensions.

    C. These channels shall be not less than 3/4-inch wide and not more than 1-1/4-inch wide and shall be cut so that a maximum 3/16-inch of the base of the locking extension remains in the base of the strap channel. Strap channels shall be provided at intervals of not less than 15-inches nor more than 20-inches center-to-center. The strap channels will not be cut through the final two locking extensions on each edge of the sheet.

    D. Transverse flaps shall be provided at the ends of sheets for pipe. Locking extensions shall be removed from flaps so that a maximum of 1/64-inch of the base of the locking extension is left on the sheet.

    E. Weld strips shall be approximately 1-inch wide with a minimum width of 7/8-inch. The edges of weld strips shall be beveled in the manufacturing process. Thickness of weld strip shall be a nominal of 1/8-inch.

    F. Joint strips for pipe shall be a minimum width of 3.75-inches. Thickness of joint strips shall be equivalent to that of the liner.

    G. Prior to preparing the sheets for shipment, they shall be tested for pinholes using an electric spark tester set at 20,000 volts minimum. Any holes shall be repaired and retested.

   PART 3 - EXECUTION

   3.01 INSTALLATION OF LINING

    A. Installation of the lining, including preheating of sheets in cold weather and the welding of all joints, shall be done in accordance with the recommendations of the manufacturer.

    B. Coverage of the lining shall be 360 degrees.

    C. The lining shall be installed with the locking extensions running parallel with the longitudinal axis of the pipe.

    D. The lining shall be held snugly in place against inner forms by means of steel banding straps or other means recommended by the manufacturer. Banding straps must be located in the precut strap channels to prevent crushing or tilting of the locking extensions.

    E. If banding straps are used, a steel channel, angle, or bar may be inserted along the edge locking extension of each liner sheet for concrete pipe. Steel channel, angle, or bar shall be of sufficient stiffness to hold the longitudinal edges of the lining snugly against the form. These may be removed after the concrete is vibrated into place.

    F. Locking extensions shall terminate not more than 1-1/2-inches from the end of the inside surface of the pipe section. Joint flaps, when used, shall extend approximately 4-inches beyond the end of the inside surface.

    G. Concrete poured against lining shall be vibrated, spaded, or compacted in a careful manner so as to protect the lining and produce a dense, homogenous concrete, securely anchoring the locking extensions into the concrete.

    H. In removing forms, care should be taken to protect the lining from damage. Sharp instruments shall not be used to pry forms from lined surfaces. When forms are removed, any nails that remain in the lining shall be pulled, without tearing the lining, and the resulting holes clearly marked. Form tie holes shall be marked before ties are broken off and all areas of serious abrasion or damage shall be marked.

    I. All nail and tie holes and all cut, torn, and seriously abraded areas in the lining shall be patched. Patches made entirely with welding strip shall be fused to the liner over the entire patch area. Larger patches may consist of smooth liner sheet applied over the damaged area with adhesive. All edges must be covered with welding strip fused to the patch and sound lining adjoining the damaged area.

    J. Hot joint compounds, such as coal tar, shall not be poured or applied to the lining.

    K. The Contractor shall take all necessary measures to prevent damage to installed lining from equipment and materials used in or taken through the work.

   3.02 APPLICATION TO CONCRETE PIPE - SPECIAL REQUIREMENTS

    A. The lining shall be set flush with the inner edge of the tongue or groove, bell or spigot end of a pipe section and shall extend to the opposite end or to approximately 4-inches beyond the opposite end, depending upon the type of lining joint to be made with the adjoining concrete pipe.

    B. Wherever concrete pipe or cast-in-place structures protected with lining join structures not so lined (such as brick structures, concrete pipe, or cast-in-place structures with clay lining or clay pipe), the lining shall be extended over and around the end of the pipe and back into the structure for not less than 4-inches. This protecting cap may be molded or fabricated from the lining material but need not be locked into the pipe.

    C. Lined concrete pipe may be cured by standard curing methods.

    D. Care shall be exercised in handling, transporting, and placing lined pipe to prevent damage to the lining. No interior hooks or slings shall be used in lifting pipe. All handling operations shall be done with an exterior sling or with a suitable fork lift.

    E. No pipe with damaged lining will be accepted until and unless the damage has been repaired in accordance with manufacturer's recommendations and to the satisfaction of the Engineer.

   3.03 FIELD JOINTS IN LINING FOR CONCRETE PIPE

    A. The joint between sections of lined pipe shall be prepared in the following manner.

    The inside joint shall be filled and carefully a painted with non-shrink cement mortar in such a manner that the mortar shall not, at any point, extend into the pipe beyond a straight line connecting the surfaces of the adjacent pipe sections.

    No lining joint shall be made until after the trench has been back-filled and consolidated or grouting operations have been completed in the tunnel portion. Pipe joints must be dry before lining joints are made.

    B. All mortar and other foreign material shall be removed from lining surfaces adjacent to the pipe joint, leaving them clean and dry.

    C. Field joints in the lining at pipe joints may be either of the following described types.

    1. Type P-1: The joint shall be made with a separate 4-inch joint strip and two welding strips. The 4-inch strip shall be centered over the joints, tack-welded to the lining, then welded along each edge to adjacent liner sheets with a 1-inch weld strip. The width of the space between adjacent sheets shall not exceed 1-inch. The 4-inch joint strip shall lap over each sheet a minimum of 1-inch.

    2. Type P-2: The joint shall be made with a joint flap with locking extensions and extending approximately 4-inches beyond the pipe end. The joint flap shall overlap the lining in the adjacent pipe section a minimum of 1-inch and be tack-welded in place prior to welding. The field joint shall be completed by welding the flap to the lining of the adjacent pipe using a 1-inch weld strip.

    Care shall be taken to protect the flap from damage. Excessive tensions and distortion in bending back the flap to expose the pipe joint during laying and joint mortaring shall be avoided. At temperatures below 50oF, heating of the liner may be required to avoid damage.

    D. The joint flap or strip on beveled pipe shall be trimmed to a width (measured from the end of the spigot) of approximately 4-inches for the entire circumferential length of the lining.

    E. Welding

    1. All welding of joints is to be in strict conformance with the specifications and instructions of the lining manufacturer.

    2. Welding shall fuse both sheets and weld strip together to provide a continuous joint equal in corrosion resistance and impermeability to the liner plate.

    3. Hot-air welding guns shall provide effluent air to the sheets to be jointed at a temperature between 500oF and 600oF. Welding guns shall be held approximately 0.5 inch from and moved back and forth over the junction of the two materials to be joined. The gun shall be moved slowly enough as the weld progresses to cause a small bead of molten material to be visible along both edges and in front of the weld strip.

   3.04 TESTING AND REPAIRING DAMAGED SURFACES

    A. After the pipe is installed in the trench or tunnel all surfaces covered with lining, including welds, shall be tested with an approved electrical hole detector (Tinker & Rasor Model No. AP-W with power pack) with the instrument set at 20,000 volts minimum.

    B. All welds shall be physically tested by a nondestructive probing method. All patches over holes, or repairs to the liner wherever damage has occurred, shall be retested.

    C. Each transverse welding strip which extends to a lower edge of the liner will be tested. The welding strips shall extend 2-inches below the liner to provide a tab. A 10-pound pull will be applied to each tab. The force will be applied normal to the face of the structure by means of a spring balance. Liner adjoining the welding strip will be held against the concrete during application of the force. The 10-pound pull will be maintained if a weld failure develops, until no further separation occurs. Defective welds will be retested after repairs have been made. Tabs shall be trimmed away neatly by the installer of the liner after the welding strip has passed inspection.

    D. All repairs shall be in accordance with manufacturer's recommendations or as directed by Engineer.

    END OF SECTION

Rembco Geotechnical Contractors specializes in slope stabilization, foundation repair and support, shoring, grouting, soil nails, micropile installations, and sinkholes. We are experienced in these applications: micro piles, sinkhole repair, permeation grouting, pressure grouting, soil nails, chemical grouting, micropiles, compaction grout, rock anchors and compaction piles. Our specialties are rock anchor, chemical and compaction grouting, mini piles, sinkhole repair, micropiles, and soil nailing. We use a problem-solving approach in the geotechnical portions of buildings, bridges, water plants, sewage plants, tunnels, sinkholes, caisson, and roads. Rembco techniques apply when adding new real estate structures: especially rock anchor, microfine grouting, soil nailing, micropile installations for foundation support. Add URL Construction, Drilling and Concrete