STATE OF OHIO DEPARTMENT OF TRANSPORTATION SUPPLEMENTAL SPECIFICATION 834 CONDUIT RENEWAL USING RESIN BASED LINER. April 16, 2010

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1 STATE OF OHIO DEPARTMENT OF TRANSPORTATION SUPPLEMENTAL SPECIFICATION 834 CONDUIT RENEWAL USING RESIN BASED LINER Description Materials Shipment and Storage Submittals Construction Method of Measurement Basis of Payment April 16, Description. This work consists of renewing a conduit by lining it with a spray applied, resin based material. The term host pipe refers to the conduit being renewed with the resin based liner system Materials. Furnish materials conforming to the following: Hydraulic cement... ASTM C 1157 Furnish resin based liner material that meets the following minimum property requirements. TABLE REQUIRED RESIN BASED LINER PROPERTIES Property Test Method Specimen Type Requirement Percent Elongation ASTM D 638 Type I, or 80% 43% Tensile Strength ASTM D 638 Type I, or Tensile Modulus ASTM D 638 Type I, or 3000 psi 2900 psi 40,000 psi 55,000 psi 20.7 MPa 20.0 MPa 276 MPa 379 MPa Flexural Modulus ASTM D ,000 psi 517 MPa Note: Specimens for testing according to ASTM D 638 may be either Type I or. 1

2 Provide one of the following resin based liner systems from the listed manufacturer. PolySpray SS100 from HydraTech, Chester Road, Cincinnati, OH Phone: (513) website: SprayShield Green II from Sprayroq, 4707 Alton Court, PO Box , Birmingham, AL 35210, Phone: (205) website: A resin based liner system from another manufacturer may be used if it meets the listed requirements and is approved by the Office of Structural Engineering. Submit to the Engineer certified test data and a letter of certification from the manufacturer that states the material conforms to the specification requirements Shipment and Storage. Inspect the containers for the base and hardener components for defects, punctures, or damage. Do not use material from defective, punctured, or damaged containers. Ensure that each container is labeled with a batch or lot number and with an expiration or use-by date. Do not use material that exceeded the expiration or use-by date. Follow the manufacturer s recommendations for shipment and storage for all products. Ensure that the material safety data sheet accompanies each material Submittals. Submit a written installation plan for the conduit renewal to the Engineer for acceptance at least ten days before beginning work. Include the following information: 1. Design calculations and shop drawings for the renewed conduit. Ensure the calculations and shop drawings address the polymer physical properties and the lining thickness as shown in the plans. 2. Methods of cleaning the host pipe 3. Plan to bypass flow around the host pipe 4. Video survey of the host pipe before installation 5. Site specific health and safety plan Allow at least ten days for review. Do not begin work until the submittals have been accepted by the Engineer. Any changes or deviations from the accepted submittals must be resubmitted. The Engineer will not grant an extension of time because of incomplete submittals. During construction, submit the following information to the Engineer. 1. Test results that demonstrate the resin based liner material meets the material requirements. Perform the tests on test coupons prepared at the project site. 2. Thickness measurements of the applied resin based material. 3. Temperature and humidity readings in the host pipe. Within two weeks of completion of the work, submit to the Engineer a video survey of the renewed conduit after installation of the resin based liner system. 2

3 Construction A. Preparation. Use any of the existing manholes in the project area to access the host pipe. If the Contractor needs to excavate to access the host pipe, coordinate the excavation work with the Engineer. Remove all debris and obstructions from the host pipe. Clean and prepare the surface of the host pipe according to the manufacturer s recommendations. B. Flow Bypassing. Install resin based liner materials in a dry host pipe. Prevent the accumulation and flow of water through the host pipe and liner until after the work is complete. Where required, bypass flows around the host pipe by plugging the host pipe at an existing upstream manhole and pumping the flow into a downstream manhole. Notify the Engineer of flow interruptions at least 14 days in advance of the interruption. Notify affected property owners and businesses at least 3 days in advance of flow interruptions. For a host pipe without manholes, such as a culvert, bypass flows around the host pipe by pumping or diverting flows through a temporary conduit or trench. After the lining process begins, maintain the bypass flow until the lining process is complete. C. Pre-Installation Inspection. After cleaning and before beginning the lining process, inspect the host pipe to ensure there are no obstructions that would hinder the lining process. Note the locations of all lateral connections to the host pipe. Perform a pre-installation video survey of the host pipe. D. Installation. Control the temperature and humidity in the host pipe according to the manufacturer s recommendation. Measure and record the temperature and humidity. Patch holes and gaps (such as weld seams and overlap joints) in the host pipe with hydraulic cement to provide a solid continuous surface on which to spray. Backfill any deep holes in the host pipe before patching with hydraulic cement. Stop water infiltration into the host pipe by applying dry hydraulic cement, filling holes with polyurethane foam, or other methods. Prepare lateral connections to the host pipe according to the manufacturer s recommendations. Protect walls, surfaces, and plants at the entrance and exit of the host pipe from overspray. Apply the resin based material to the prepared surface using methods that provide a uniform surface. Record the batch or lot number from the containers used each day. Prepare at least two test coupons by covering a flat and smooth surface with a non-stick material and applying the resin based material in the same manner and with the same equipment as used for the work. Ensure the liner is continuous over the entire length of the host pipe and free from defects such as foreign inclusions, holes and cracks. Ensure the renewed conduit is impervious to infiltration and exfiltration. Contain, collect, characterize and legally dispose of all waste generated during the work Manage all waste streams in accordance with ORC Chapter 6111 and all other laws, regulations, permits and local ordinances relating to this waste. 3

4 E. After Installation. At all locations where excavations expose the host pipe or lateral connections, encase the exposed host pipe or lateral connections with concrete, low strength mortar backfill, or other suitable material according to 603 or 604 as appropriate. Backfill excavations according to or as appropriate. Repair all defects in the resin based liner which will or potentially could affect the performance or structural integrity of the renewed conduit. Perform all repairs at no expense to the Department Method of Measurement. The Department will measure Conduit Renewal Using Resin Based Liner in pipes by the number of feet of host pipe length. If Conduit Renewal Using Resin Based Liner, measured by square feet (square meters) is specified, the Department will measure by the number of square feet (square meters) of surface area covered by the resin based liner material Basis of Payment. Payment for conduit renewal includes excavation, backfill, encasement, inspections, and all other work required to complete the specified items. The Department will pay for accepted quantities at the contract price as follows: Item Unit Description 834 Foot (Meter) Conduit Renewal Using Resin Based Liner, " ( mm) Diameter 834 Square Feet Conduit Renewal Using Resin Based Liner (Square Meter) 4

5 Designer Note: This specification may be used for relining existing conduit that is 36-inch diameter or greater in size Contact the manufacturers for the required thickness of the liner. Take the greatest thickness from all the manufacturers and specify that thickness on the plans. Typically, use the linear foot pay item. This pay item is intended for round pipes. Specify the pipe diameter in the pay item description. Use the square foot pay item if the conduit is a larger structure, such as a box or three sided culvert. Contact the Hydraulic Section of the Office of Structural Engineering if there are any questions or concerns (such as excessive deflection or profile concerns) with using this specification. 5