Loading...
19-0115_SANCON ENGINEERING, INC_Technical Specifications (Conformed Set) Annual Sewer Rehabilitation Program, CIP 18701 Technical Specifications Cover Sheet City of San Juan Capistrano TECHNICAL SPECIFICATIONS FOR THE ANNUAL SEWER REHABILITATION PROGRAM, CIP 18701 Sewer Rehabilitation Program, CIP 18701 THIS PAGE IS LEFT INTENTIONALLY BLANK SECTION 01025 MEASUREMENT AND PAYMENT Sewer Rehabilitation Program - CIP 18701 Measurement and Payment 01025- 1 GENERAL 1.01 REQUIREMENTS PER GENERAL PROVISIONS A. Monthly pay requests are due on a certain day of each month (to be established at the Pre- Construction Meeting), and while pay requests will be accepted prior to this date, pay request processing will not begin until this date. Failure of the Contractor to submit pay requests by this day may be cause for delays in processing the pay request. Should the submittal date fall on a holiday or weekend day during the month, then the Contractor shall consider the next working day as the due date. 1.02 BID PROPOSAL A. Measurement and payment shall be in accordance with the General Conditions and as follows: 1. Unit Prices: Payment for a unit price bid item shall be based upon the amount shown in the bid schedule multiplied by the total quantity measurement of the installed item and shall be full compensation for furnishing all labor, transportation, materials, equipment, tools and appurtenances required for construction of the item complete in place in accordance with the Contract Documents. 2. Lump Sum Prices: The Contractor shall provide Lump Sum and Total Cost Prices in the Bid Schedule for all Lump Sum work items of work in the Contract Documents. Each Lump Sum price shall cover all costs and charges, including, without limitation, the costs of material, labor, fabrication, delivery, installation or application, transportation, fuel, supervision, overhead, profit, and taxes needed for a complete and working installation as required by the Contract Documents. Lump Sum prices provided to the City shall be held good and in effect until the work is completed and accepted by City. Contractor proposed prices which are so unbalanced as to be detrimental to the City’s interest, as determined by the City, may be rejected, or may be cause for revision without revising the total bid amount, or may cause rejection of the Bidder's entire bid, all at the sole discretion of the City. 3. Retention: Payment for all bid items is subject to the retention provisions of the General Conditions. 1.03 MEASUREMENT AND PAYMENT A. General: This article defines the manner and method to develop the bid amounts of all items identified in the Bid Schedule. Bid amounts will include the costs of all labor, equipment, tools, materials, fees, subcontractors, support services, safety requirements, and any and all other items required to complete the work identified in the Contract Documents unless specifically excluded by this section. Work required for which no separate bid item is identified will be considered as a subsidiary obligation of the City of San Juan Capistrano Measurement and Payment Sewer Rehabilitation Program - CIP 17808 01025- 2 Contractor, and the cost therefore shall be borne solely by the Contractor and included in the most applicable bid item. B. Linear Measurements: Pipelines' and related facilities' measurements shall be made horizontally and/or vertically along the centerline of the pipeline and related facilities through tees, bends, valves, fittings, and as shown on the Approved Plans for its limits or as otherwise specified in the Specifications. C. Area Measurements: Measurement for bid items involving area units shall be based upon the surface area measured in acres, square yards, square feet or as indicated in the bid item. D. Volume Measurements: Measurement for bid items involving volume units shall be based upon the volume measured in cubic yards, tons or as indicated in the bid item. E. Unit Measurements: Measurement for bid items involving units of the item shall be based upon the number of units counted as indicated in the bid item. F. Lump Sum Measurement: Measurement for a lump sum bid item shall be considered as a complete project or a completed portion of a project constituting a unit. The items to be included in the lump sum bid shall be as specified in the proposal bid item. CONTRACT REQUIRED WORK - BID ITEMS 2.01 SEWER REHABILITATION PROGRAM - CIP 18701: A. MOBILIZATION/DEMOBILIZATION (BID ITEM NO. 1) 1. Payment for mobilization and preparatory work will be made at the Contract lump sum price bid therefore in the Bid Schedule, in accordance with the Contract Documents. The Contract lump sum price shall include full compensation for furnishing all labor, tools, equipment, materials and incidentals, and for doing all work involved in mobilization and preparatory work, and for which payment is not otherwise provided for under the Contract, and no additional compensation will be made therefore. 2. The lump sum bid price shall include, but not be limited to, the cost of movement of personnel, equipment, supplies and incidentals to the project site; for the establishment of offices and temporary facilities and services at the project site; for the securing of Insurances and City Business License, and for all permits (all agencies) and compliance required for the work unless otherwise included under other items of the bid schedule; for payment of premiums for bonds and insurance for the project; for any and all necessary costs of acquisition of equipment, including purchase and mobilization; for provision, environmental quality protection in accordance with Appendix E and sub-section 3.9 of the General Requirements, section 01 00 00 of these specifications, demobilization and any other work and operations which must be performed or costs that must be incurred incident to the initiation and completion of meaningful work at the site, all in conformance with the Contract Documents. City of San Juan Capistrano Measurement and Payment Sewer Rehabilitation Program - CIP 17808 01025- 3 3. When other Contract items are adjusted, mobilization and preparatory work costs will be deemed to have been recovered by the Contractor by the payments made for the mobilization and preparatory work, and will be excluded from consideration in determining compensation therefore. Progress payments for the mobilization and preparatory work shall be subject to retainage as provided within the Contract Documents. B. ORANGE COUNTY FLOOD CONTROL DISTRICT (OCFCD) INSURANCE AND PERMIT COMPLIANCE, COMPLETE (BID ITEM NO. 2) 1. Payment for OCFCD insurance and permit compliance will be made at the Contract lump sum price bid therefore in the Bid Schedule, complete in place, in accordance with the Contract Documents. The lump sum price for this work shall be per this bid item and no additional compensation will be allowed. The Contract lump sum price bid shall include full compensation for furnishing all labor, tools, equipment, materials and incidentals, and for doing all work involved with providing insurance in accordance with OCFCD requirements, and abiding by all permit conditions for all work within OCFCD right of way, all for which payment is not otherwise provided for under other items of the bid schedule, and no additional compensation will be made therefore. 2. The Contract lump sum price shall include, but not be limited to the cost of obtaining the necessary insurance and complying with all conditions of the permit, all in conformance with the Contract Documents, complete in place and fully operational, with no interruption in service. C. SOUTHERN CALIFORNIA REGIONAL RAIL AUTHORITY (SCRRA) RIGHT OF ENTRY AGREEMENT – APPLICATION AND FEES (BID ITEM NO. 3) 1. Payment for SCRRA Right of Entry Agreement will be made at the Contract lump sum price bid therefore in the Bid Schedule, complete in place, in accordance with the Contract Documents. The lump sum price for this work shall be per this bid item and no additional compensation will be allowed. The Contract lump sum price bid shall include full compensation for furnishing all labor, tools, equipment, materials and incidentals, and for doing all work involved with constructing SCRRA Right of Entry Agreement, and for which payment is not otherwise provided for under the Contract, and no additional compensation will be made therefore. 2. The Contract lump sum price bid shall include, but not be limited to the cost of filling out and submitting the application and paying all fees to secure and abide by the right of entry agreement, including but not limited to plan review, administration, insurance, safety training, flagging, protective services, and all other costs associated with the Right of Entry Agreement all in conformance with the Contract Documents, complete in place and fully operational with no interruption in service. D. SHEETING, SHORING AND BRACING (BID ITEM NO. 4) 1. Payment for sheeting, shoring and bracing will be made at the Contract lump sum price bid therefore in the Bid Schedule, complete in place, in accordance with the Contract Documents. The lump sum price for this work shall be per this bid item and no additional City of San Juan Capistrano Measurement and Payment Sewer Rehabilitation Program - CIP 17808 01025- 4 compensation will be allowed. The Contract lump sum price bid shall include full compensation for furnishing all labor, tools, equipment, materials and incidentals, and for doing all work involved with constructing sheeting, shoring and bracing for which payment is not otherwise provided for under the Contract, and no additional compensation will be made therefore. 2. The Contract lump sum price bid shall include, but not be limited to the cost to furnish and install sheeting, shoring and bracing as required by Cal-Osha to ensure safety of workers in areas of excavation, all in conformance with the Contract Documents, complete in place and fully operational. E. TRAFFIC CONTROL, PUBLIC CONVENIENCE AND SAFETY (BID ITEM NO. 5) 1. Payment for Traffic Control, Public Convenience and Safety will be made at the Contract lump sum price bid therefore in the Bid Schedule, complete in accordance with the Contract Documents. The Contract lump sum price shall include full compensation for furnishing all labor, tools, equipment, materials and incidentals and for doing all work involved in providing Traffic Control, Public Convenience and Safety as required and at multiple locations as dictated by the Contract Documents, and no additional compensation will be allowed therefore. 2. The Contract lump sum price bid shall include, but not be limited to the cost of implementing the measures specified in Section 7-10 of the Green Book, required traffic and pedestrian control, and safety orders as defined in the City of San Juan Capistrano Encroachment Permit Conditions, Manual of Uniform Traffic Control Devices, and in accordance with all Cal Osha requirements, federal state and local regulations, in order to allow for safe performance of the work described in these Contract Documents. Work in the California State Department of transportation (Caltrans) right of way is also subject to Caltrans Permit conditions. F. POTHOLING (BID ITEM NO. 6) 1. Payment for potholing will be made at the Contract unit price bid therefore in the Bid Schedule, complete in place, in accordance with the Contract Documents. The unit price for this work shall be per this bid item and no additional compensation will be allowed. The Contract unit price bid shall include full compensation for furnishing all labor, tools, equipment, materials and incidentals, and for doing all work involved with potholing, and for which payment is not otherwise provided for under the Contract, and no additional compensation will be made therefore. 2. The Contract unit price bid shall include, but not be limited to the cost to furnish all materials and labor to pothole locate all utilities in the project area that are incidental to the work or are in conflict with the alignments shown on the Construction Drawings, furnishing the City with a pothole report that lists at a minimum the location, type, depth, diameter and material of the utility being protected in place, backfill, compaction and surface restoration, complete in place and in conformance with the Contract Documents. G. DIG AND REPLACE 6” AND 8” SEWER LINE, DEPTH ≤ 10 FEET (BID ITEM NO. 7) City of San Juan Capistrano Measurement and Payment Sewer Rehabilitation Program - CIP 17808 01025- 5 1. Payment for dig and replace 6” and 8” sewer line, depth less than or equal to ten feet will be made at the Contract unit price bid therefore in the Bid Schedule, complete in place, in accordance with the Contract Documents. The unit price for this work shall be per this bid item and no additional compensation will be allowed. The Contract unit price bid shall include full compensation for furnishing all labor, tools, equipment, materials and incidentals, and for doing all work involved with this dig and replace item, and for which payment is not otherwise provided for under other items of the bid schedule, and no additional compensation will be made therefore. 2. The Contract unit price bid shall include, but not be limited to the cost to furnish all materials and labor to dig and replace 6” and 8” sewer line, depth less than or equal to 10 feet, including but not limited to sawcut and remove pavement, excavation to expose sewer line, bypass pumping to dewater the line, cut and remove compromised portion of pipeline and dispose of all waste material in accordance with all federal, state and local regulations, furnish and install replacement pipeline of equal diameter with band couplings as indicated on the detail in appendix A, bedding, backfill and compaction, and pavement replacement per City standard 700, complete in place and fully operational in conformance with the Contract Documents. H. DIG AND REPLACE 6” AND 8” SEWER LINE, DEPTH > 10 FEET (BID ITEM NO. 8) 1. Payment for dig and replace 6” and 8” sewer line, depth greater than ten feet will be made at the Contract unit price bid therefore in the Bid Schedule, complete in place, in accordance with the Contract Documents. The unit price for this work shall be per this bid item and no additional compensation will be allowed. The Contract unit price bid shall include full compensation for furnishing all labor, tools, equipment, materials and incidentals, and for doing all work involved with this dig and replace item, and for which payment is not otherwise provided for under other items of the bid schedule, and no additional compensation will be made therefore. 2. The Contract unit price bid shall include, but not be limited to the cost to furnish all materials and labor to dig and replace 6” and 8” sewer line, depth greater than 10 feet, including but not limited to saw-cut and remove pavement, excavation to expose sewer line, bypass pumping to dewater the line, cut and remove compromised portion of pipeline and dispose of all waste material in accordance with all federal, state and local regulations, furnish and install replacement pipeline of equal diameter with band couplings as indicated on the detail in appendix A, bedding, backfill and compaction, and pavement replacement per City standard 700, complete in place and fully operational in conformance with the Contract Documents. I. TEMPORARY SEWER BYPASS 6” & 8” (BID ITEM NO.’S 9 AND 11) 1. Payment for Temporary Sewer Bypass will be made at the Contract lump sum price bid (separate price for each pipe size and respective bid item numbers listed above) therefore in the Bid Schedule, complete and in accordance with the Contract Documents. The Contract lump sum price shall include full compensation for furnishing all labor, power, tools, equipment, materials, appurtenances and City of San Juan Capistrano Measurement and Payment Sewer Rehabilitation Program - CIP 17808 01025- 6 incidentals and for doing all work involved in providing temporary sewer bypass facilities of each size, and no additional compensation will be allowed therefore. 2. The Contract lump sum price shall include, but not be limited to the cost of providing all required equipment such as pumps, generators, piping, valving, site cleanup and restoration, all in conformance with the Contract Documents, complete in place and fully operational, J. CURED IN PLACE PIPE 6”, 8”, 15”, 18” (BID ITEM NO.’S 10, 12, 13, 14 & 15) 1. Payment for Cured-In-Place-Pipe, Diameter as indicated in the bid schedule, will be made at the Contract unit price bid (separate price for each pipe size and respective bid item number listed above) therefore in the Bid Schedule, complete in accordance with the Contract Documents. The unit price for this work shall be per the corresponding bid item and no additional compensation will be allowed. The Contract unit price bid for each item shall include full compensation for furnishing all labor, tools, equipment, materials and incidentals, and for doing all work involved with constructing cured-in-place-pipe of each size, and no additional compensation will be made for the bid items listed therefore. 2. The Contract unit price bid shall include, but not be limited to the cost of pre-bid verification of diameter and linear length, pre-installation inspection video, sewer cleaning, removal and disposal of material not otherwise covered under item K below, to provide an unimpeded flow diameter and thereby make way for the cured in place pipe, installation and curing of liner, trimming, sealing and finishing manhole connection, reestablishing laterals and post-construction video, cost for temporary sewer bypass for 15 inch short liner if necessary, all in conformance with industry standard practices and the Contract Documents, complete in place and fully operational with no interruption in service. K. CUT AND REMOVE PROTRUDING LATERALS, HANGING GASKETS, ROOT BALLS AND OTHER OBSTRUCTIONS (BID ITEM NO. 16) 1. Payment for removal of protruding laterals, hanging gaskets and other obstructions to make way for installation of Cured in Place Pipe will be made at the unit price indicated in the Bid Schedule, complete in accordance with the Contract Documents. The unit price for this work shall be per the corresponding bid item and no additional compensation will be allowed. The Contract unit price bid for each item shall include full compensation for furnishing all labor, tools, equipment, materials and incidentals, and for doing all work involved with removal and disposal of protruding laterals, hanging gaskets, root balls and other obstructions to make way for installation of cured in place pipe, and no additional compensation will be made therefore. 2. The Contract unit price bid shall include, but not be limited to the cost of removing protruding laterals, hanging gaskets, root balls and other obstructions, with robotic cutting and grinding tools, or by other means, in which case the bid item includes the cost of adherence to confined space entry program in accordance with Greenbook Section 7-10.4.4 and all Cal Osha requirements, all in conformance with City of San Juan Capistrano Measurement and Payment Sewer Rehabilitation Program - CIP 17808 01025- 7 industry standard practices and the Contract Documents, complete in place and fully operational with no interruption in service. L. MANHOLE REHABILITATION WITH PRESSURE GROUTING (BID ITEM NO. 17) 1. Payment for Manhole Rehabilitation with pressure grouting will be made at the Contract unit price bid therefore in the Bid Schedule, complete in place, in accordance with the Contract Documents. The unit price for this work shall be per this bid item and no additional compensation will be allowed. The Contract unit price bid shall include full compensation for furnishing all labor, tools, equipment, materials and incidentals, and for doing all work involved with constructing Manhole Rehabilitation with pressure grouting, and for which payment is not otherwise provided for under the Contract, and no additional compensation will be made therefore. 2. The Contract unit price bid shall include, but not be limited to the cost of manhole cleaning, remove corroded metal access steps and grind flush with manhole wall, reconstruction of manhole bench and channels, root removal, crack and infiltration repair, pressure grouting of all manholes with root intrusion and evidence of infiltration, surface preparation and spray application of calcium aluminate mortar seal in accordance with the manufacturer’s instructions, all in conformance with the Contract Documents, complete in place and fully operational with no interruption in service. M. MANHOLE REHABILITATION WITHOUT PRESSURE GROUTING (BID ITEM 18) 1. Payment for Manhole Rehabilitation without pressure grouting will be made at the Contract unit price bid therefore in the Bid Schedule, complete in place, in accordance with the Contract Documents. The unit price for this work shall be per this bid item and no additional compensation will be allowed. The Contract unit price bid shall include full compensation for furnishing all labor, tools, equipment, materials and incidentals, and for doing all work involved with constructing Manhole Rehabilitation without pressure grouting, and for which payment is not otherwise provided for under the Contract, and no additional compensation will be made therefore. 2. The Contract unit price bid shall include, but not be limited to the cost of manhole cleaning, remove corroded metal access steps and grind flush with manhole wall, reconstruction of manhole bench and channels, root removal, crack and infiltration repair, surface preparation and spray application of calcium aluminate mortar seal in accordance with the manufacturer’s instructions, all in conformance with the Contract Documents, complete in place and fully operational with no interruption in service. N. MANHOLE FRAME AND COVER (BID ITEM NO. 19) 1. Payment for manhole frame and cover will be made at the Contract unit price bid therefore in the Bid Schedule, complete in place, in accordance with the Contract Documents. The unit price for this work shall be per this bid item and no additional compensation will be allowed. The Contract unit price bid shall include full City of San Juan Capistrano Measurement and Payment Sewer Rehabilitation Program - CIP 17808 01025- 8 compensation for furnishing all labor, tools, equipment, materials and incidentals, and for doing all work involved with constructing manhole frame and cover, and for which payment is not otherwise provided for under the Contract, and no additional compensation will be made therefore. 2. The Contract unit price bid shall include, but not be limited to the cost of preparing the manhole, furnish and install the new manhole frame and cover in accordance with City of San Juan Capistrano standard plan no. 807, haul and dispose of old manhole frame and cover at an approved facility in accordance with all federal state and local regulations, all in conformance with the Contract Documents, complete in place and fully operational with no interruption in service. O. SERVICE LATERAL CONNECTION REPAIR - TOP HAT STYLE (BID ITEM NO. 20) 1. Payment for Service Lateral Connection Repair - Top Hat Style will be made at the Contract unit price bid therefore in the Bid Schedule, complete in place, in accordance with the Contract Documents. The unit price for this work shall be per this bid item and no additional compensation will be allowed. The Contract unit price bid shall include full compensation for furnishing all labor, tools, equipment, materials and incidentals, and for doing all work involved with Top Hat Style Lateral Repair in accordance with the Contract Documents, and no additional compensation will be made therefore. 2. The Contract unit price bid shall include, but not be limited to the cost of pre-bid verification of diameter and linear length, pre-installation video, sewer cleaning, removal of roots and obstructions to allow for proper installation of top hat liner, installation and curing of liner, trimming and finishing, post-construction video, and all associated work to provide a neat and fully functional top hat style lateral repair and connection in accordance with industry standard practices and in accordance with the Contract Documents, complete in place and fully operational with no interruption in service. P. RAISE MANHOLE (BID ITEM NO. 21) 1. Payment for raise manhole will be made at the contract unit price bid therefore in the Bid Schedule, complete in accordance with the Contract Documents. The Contract unit price shall include full compensation for furnishing all labor, tools, equipment, materials, appurtenances and incidentals and for doing all work involved in raising manholes to grade, and no additional compensation will be made therefore. 2. The Contract unit price shall include, but not be limited to the cost of excavation to expose existing top of manhole, remove existing frame and cover and salvage to City staff, clean and prep existing manhole top section, furnish and install concrete riser, cone and grade ring, seal all joints, furnish and install new frame and cover with grout seal, backfill and compact per City standards and in accordance with the raise manhole detail in appendix A, complete in place and fully operational. City of San Juan Capistrano Measurement and Payment Sewer Rehabilitation Program - CIP 17808 01025- 9 Q. RAISE CLEANOUT (BID ITEM NO. 22) 1. Payment for raise cleanout will be made at the contract unit price bid therefore in the Bid Schedule, complete in accordance with the Contract Documents. The Contract unit price shall include full compensation for furnishing all labor, tools, equipment, materials, appurtenances and incidentals and for doing all work involved in raising cleanout to grade, and no additional compensation will be made therefore. 2. The Contract unit price shall include, but not be limited to the cost of excavation to expose existing top of cleanout, remove existing frame and cover and salvage to City staff, clean and prep existing cleanout top section, furnish and install pipe riser to match existing diameter and solvent weld coupling to grade, furnish and install new frame and cover backfill and compact per the raise cleanout detail in Appendix A, and in accordance with the Contract Documents, complete in place and fully operational. EXECUTION 3.01 GENERAL PROGRESS PAYMENT REQUIREMENTS A. The City Representative will verify measurements and quantities. Each activity necessary to manage and complete the work is identified on the contract schedule. Each activity will be assigned its respective value, a portion of the contract price, as shown on the Schedule of Values. B. Payment for all lump sum costs and services incurred on this Contract shall be based on the earned value of work accomplished during the reporting period. Earned value is determined by the completion percentage of each activity applied to the total value of the activity. No construction activity shall be deemed 100% complete until the Contractor has completed the physical check out and inspection of the completed work and has submitted the signed inspection form to the City Representative. C. The Contractor shall not take advantage of any apparent error or omission on the Drawings of Specifications, and the City Representative shall be permitted to make corrections and interpretations as may be deemed necessary for fulfillment of the intent of the Contract Documents at no additional cost to the City. D. One legible copy of the application for payment shall be submitted. Application shall be made monthly. E. The Application for Payment shall contain all necessary references and attachments that substantiate the invoice for progress payment; including, but not limited to the following: Summary of Earned Value on a percent complete basis, as confirmed by both the City inspector and the project manager. F. The Application for Payment is submitted according to the format and instructions provided by the City and is based on work completed through the last day of the previous month or through the date established by the City Representative. END OF SECTION 01025 Sewer Rehabilitation Program, CIP 18701 THIS PAGE IS LEFT INTENTIONALLY BLANK Sewer Rehabilitation Program, CIP 18701 13500 - 1 CURED-IN-PLACE-PIPE SECTION 13500 – CURED-IN-PLACE-PIPE (CIPP) PART 1 - GENERAL 1.1 INTENT A. It is the intent of this specification to provide for the rehabilitation of sewers by the installation of a resin-impregnated flexible liner, which is inserted using an inversion process to fit tightly against the original host pipe. The resin is cured using hot water, steam or ultraviolet light (UV). The cured-in-place-pipe (CIPP) will be continuous and tight fitting. B. Contractor shall provide materials, labor, equipment, and services necessary for pre-installation cleaning, rehabilitation of existing sewer pipes by lining, reinstatement of lateral connections, initial and final closed circuit television inspection, and final testing of the CIPP system. 1.2 RELATED DOCUMENTS A. This specification references standards from the American Society for Testing and Materials, such as: 1. ASTM F1216 (Rehabilitation of Existing Pipelines and Conduits by the Inversion and Curing of a Resin-Impregnated Liner); 2. ASTM F1743 (Rehabilitation of Existing Pipelines and Conduits by Pulled- in-Place Installation of Cured-in-Place Thermosetting Resin Pipe (CIPP)); 3. ASTM D5813 (Cured-in-Place Thermosetting Resin Sewer Pipe); 4. ASTM D790 (Test Methods for Flexural Properties of Un-reinforced and Reinforced Plastics and Electrical Insulating Materials); and 5. D2990 (Tensile, Compressive, and Flexural Creep and Creep-Rupture of Plastics). 1.3 SUBMITTALS – As a minimum, Contractor shall submit the following for review: A. Liner, resin, sealant fittings, adapters and specials. B. The standard dimension ratio is the ratio of the outside diameter of the pipe to its minimum wall thickness. All CIPP wall thicknesses calculated by a Sewer Rehabilitation Program, CIP 18701 13500 - 2 CURED-IN-PLACE-PIPE professional engineer registered in the state of California, SDR’s by diameter, and depth ranges corresponding to this specification, shall be submitted to the engineer for approval prior to installation. C. Critical Damage Reports as described in this specification, if applicable. D. The contractor shall submit to the City at least 24 hours prior to installation, a “wet out” schedule detailing time and location. E. The manufacturer, prior to installation, shall provide the inversion pressures necessary for proper installation. Installation forces shall be limited so the liner is not stretched longitudinally by more than 5% of the original length. F. Before installation begins, the tube manufacturer shall provide the minimum pressures required to hold the tube tight against the existing host pipe, and the maximum allowed pressure that will not damage the tube. G. Acceptance testing samples as described in section 2.4. H. Copy of the Southern California Regional Rail Authority right of entry permit for work within the railroad right of way shall be submitted to the City prior to commencing work. I. Pre and Post Construction CCTV videos. J. Certificates and Affidavits (to be furnished prior to shipment) 1. Affidavit of compliance with applicable standards for resins and liner materials. 2. Certification that Contractor is a licensed installer of any patented process. 1.4 PRODUCT, MANUFACTURER AND INSTALLER QUALIFICATION REQUIREMENTS A. The sewer repairs specified herein are intended to have a 50-year design life. In order to minimize the Owner’s risk, only proven products with substantial successful long-term track records will be approved. All trenchless rehabilitation products and installers must meet the minimum requirements of these specifications. B. Products and Installers seeking approval must meet all of the following criteria to be deemed Commercially Acceptable: 1. For a Product Manufacturer to be considered Commercially Proven, a minimum of 1,000,000 linear feet or 4,000 manhole-to-manhole line sections of successful wastewater collection system installations in the U.S. must be documented to the satisfaction of the Owner to assure commercial viability. Acceptable documentation indicating that this Sewer Rehabilitation Program, CIP 18701 13500 - 3 CURED-IN-PLACE-PIPE requirement has been satisfied must be submitted to the Engineer for review. 2. For an Installer to be considered as Commercially Proven, the Installer must have had at least 5 (five) years active continuous experience in the commercial installation of cured-in-place-pipe. In addition, the Installer must have successfully installed at least 50,000 feet of the CIPP in wastewater collection systems. Acceptable documentation indicating that this requirement has been satisfied must be submitted to the Engineer for review. 3. Sewer rehabilitation products submitted for approval must provide third party test results supporting the structural performance (short-term and long-term) of the product and such data shall be satisfactory to the City. Test samples shall be prepared so as to simulate installation methods and trauma of the product. Products without independent third party testing verification are not acceptable. Acceptable documentation indicating that this requirement has been satisfied must be submitted to the City for review. 4. Both the rehabilitation manufacturing and installation processes shall operate under a quality management system which is third-party certified to ISO 9000 or other recognized organization standards. Proof of certification shall be required for approval. Acceptable documentation indicating that this requirement has been satisfied must be submitted to the Engineer for review. 1.5 BIDDER’S INSPECTION – Bidder shall examine CCTV video files of sewers provided by the City on a web based account and become familiar with the existing sewer and site conditions prior to submitting a bid. Location of the web based account will be provided by the City during the bidding phase of the project. PART 2 - PRODUCTS 2.1 MATERIALS A. Liner - The sewn liner shall consist of one or more layers of absorbent non- woven felt fabric and meet the requirements of ASTM F1216, Section 5.1 or ASTM F1743, Section 5.2.1 The liner shall be constructed to withstand installation pressures, have sufficient strength to bridge missing pipe, and stretch to fit irregular pipe sections. 1. The wet out liner shall have a relatively uniform thickness that when compressed at installation pressures will equal or exceed the calculated minimum design thickness. Sewer Rehabilitation Program, CIP 18701 13500 - 4 CURED-IN-PLACE-PIPE 2. The liner shall be manufactured to a size that when installed will tightly fit the internal circumference and length of the original pipe. Allowance should be made for circumferential stretching during inversion. Overlapped layers of felt in longitudinal seams that cause lumps in the final product shall not be utilized. 3. The outside layer of the liner shall be coated with an impermeable, flexible membrane that will contain the resin and all the resin impregnation (wet out) procedure to be monitored. 4. The liner shall be homogeneous across the entire wall thickness containing no intermediate or encapsulated elastomeric layers. No material shall be included in the liner that may cause delamination in the cured CIPP. No dry or unsaturated layers shall be evident. 5. The wall color of the interior pipe surface of CIPP after installation shall be a relatively light reflective color so that a clear detailed examination with closed circuit television inspection equipment may be made. 6. Seams in the liner shall be stronger than the non-seamed felt material. 7. The liner shall be marked for distance at regular intervals along its entire length, not to exceed 5 ft. Such markings shall include the manufacturers name or identifying symbol. B. Resin - The resin system shall be a corrosion resistant polyester, vinyl ester, or epoxy system including all required catalysts, initiators or hardeners that when cured within the liner create a composite that satisfies the requirements of ASTM F1216 and ASTM F1743, the physical properties herein, and those which are to be utilized in the design of the CIPP for this project. The resin shall produce a CIPP that will comply with the structural and chemical resistance requirements of this specification. 2.2 STRUCTURAL REQUIREMENTS A. The CIPP shall be designed per ASTM F1216, Appendix X.1. The CIPP design shall be based on the assumption that no bonding to the original pipe wall occurs. B. 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 the layers separate during field sample testing, new samples will be required to be obtained from the installed pipe. Any reoccurrence will serve as grounds for rejection of the work. C. The cured in place pipe material (CIPP) shall conform to the structural properties, as listed below. Sewer Rehabilitation Program, CIP 18701 13500 - 5 CURED-IN-PLACE-PIPE Material Strength Standards Property Test Method Low Modulus High Modulus Modulus of Elasticity ASTM D790 300,000 PSI 400,000 PSI Flexural Strength ASTM D790 5,500 PSI Tensile Strength ASTM D638 3,000-5,000 PSI Tensile Load Capacity per layer ASTM D638 775 lbs/inch D. The required structural CIPP wall thickness shall be based as a minimum, on the physical properties identified above and in accordance with the design considerations and equations in ASTM F1216 and its Appendix X1, and the following design parameters: 1. Design Life = 50 years 2. Minimum Design Safety Factor = 2.0 3. Retention Factor for Long-Term Flexural Modulus = 50% 4. Ovality (calculated per ASTM F1216 X1.1) = 2% 5. Enhancement Factor, K = 7 6. The CIPP is subject to a groundwater elevation 5 feet below the ground surface. 7. Soil Depth (above crown of existing pipe) per table in sec 013500, part 1.1.B 8. Soil Modulus = 1,000-psi 9. Soil Density = 120-pcf 10. Highway Live Load = AASHTO HS20-44 11. Design Condition = fully deteriorated, no existing pipe strength. 12. Minimum thickness shall be per the table in section 2.3 below 13. If calculations require thicker wall, round to next higher multiple of 0.5mm E. Layers of the liner that are not saturated with resin prior to insertion into the existing pipe shall not be included in the required design structural CIPP wall thickness. Sewer Rehabilitation Program, CIP 18701 13500 - 6 CURED-IN-PLACE-PIPE 2.3 LINING DESIGN – The minimum CIPP liner thickness for the various sewer diameters shall be no less than indicated below. Minimum CIPP Thickness Nominal Sewer Diam- eter (inches) Pipe Invert Depth Up to 10 feet (mm) 10 – 15 feet (mm) 15 – 20 feet (mm) 20-25 feet (mm) 6 4.5 4.5 4.5 6.0 8 6.0 6.0 6.0 7.5 10 6.0 7.5 7.5 9.0 12 7.5 7.5 9.0 10.5 15 9.0 10.5 12.0 12.0 18 10.5 12.0 13.5 15.0 21 12.0 13.5 16.5 18.0 36 19..5 24.0 27.0 30.0 These values represent the minimum thickness for the installed CIPP after curing has been completed based on the following design assumptions: 1. The existing sewer is considered fully deteriorated. 2. The existing sewer is considered to have an ovality of 2 percent in circum- ference. 3. The CIPP is subjected to a full soil load of 120 pounds per cubic foot. 4. The CIPP is subjected to traffic line loads as calculated by AASHTO Standard Specifications for Highway Bridges, HS-20-44 Highway Loading. 5. The modulus of soil reaction for pipe zone backfill material is 700 psi. 6. The CIPP is subject to a groundwater elevation 5 feet below the ground surface. 7. The CIPP Flexural Strength shall be 4,500 psi (ASTM D-790). 8. The CIPP Short term flexural Modulus of Elasticity shall be 250,000 psi (ASTM D-790). 2.4 TESTING REQUIREMENTS A. Gravity pipe leakage testing – For 24 inch diameter or less, CIPP low pressure air test per City of San Juan Capistrano (CSJC) standard specification section I- 08 shall be required after liner has been installed in existing pipe. For pipe diameters greater than 24 inches, follow the infiltration testing requirements of CSJC standard specification section I-08. B. CIPP properties test – One minimum 12 inch long restrained pipe section shall be cut from the cured liner of each segment and labeled with upstream and downstream manholes numbers for that section. Contractor shall submit the sample to the City with thickness measurements taken and witnessed by the Sewer Rehabilitation Program, CIP 18701 13500 - 7 CURED-IN-PLACE-PIPE City inspector, from four locations on each test section. The average thickness of the measurements shall be equal to or greater than the required minimum or design thickness (whichever is greater). In addition, Contractor shall collect the coupons from the service line connection restorations for each setup tested, label with upstream and downstream manhole numbers, and submit to the City. These coupons will be used for testing liner thickness. Failure of the thickness test shall be grounds for rejection of the CIPP liner. C. Resin properties test – “Wet-out” facility resin mixing equipment shall have a valve downstream of the mixing functions and immediately upstream of the application of the mixed resin to the tube where the City can draw resin samples. Sampling and testing of the mixed batch shall be conducted by a laboratory approved by the City. Submitted “wet-out” schedule cannot be modified without 24 hour notice to the City. The City representative drawing the samples will arrive unannounced and shall be afforded immediate access to the equipment. D. CCTV Visual Test – The Contractor shall inspect each installation visually by CCTV. Variations from true line and grade may be inherent because of conditions of the original piping. No infiltration of groundwater shall be observed. All lateral entrances shall be accounted for and be fully functional. No visible leak around liner at manhole connections will be allowed. The pre and post installation video data shall be submitted to and will become the property of the City. E. Contractor shall correct liner that has failed any of the above tests. Remedy for failed thickness test shall be defined as shown in the following table. Where liner removal and replacement is required, it shall be for the entire segment length from manhole to manhole. No additional payment shall be made for removal and replacement of faulty liners. Pipe Correction Test Required Value Test Result Remedy Thickness, (T) Minimum or Design, whichever is greater >=90% to 100% No unit price reduction 90% > T >=80% 15% Unit Price Reduction < 80% Liner Replacement 2.5 DELIVERY AND STORAGE – Delivery and storage of lining and other materials shall conform to the published requirements of the manufacturer. Contractor is responsible to furnish required storage facilities. Handle lining materials in Sewer Rehabilitation Program, CIP 18701 13500 - 8 CURED-IN-PLACE-PIPE compliance with manufacture’s published recommendations. Damaged material will be unacceptable for installation. PART 3 - EXECUTION 3.1 INSTALLATION RESPONSIBILITIES FOR INCIDENTAL ITEMS A. It shall be the responsibility of Contractor to locate and verify the designated manholes are adequately accessible for the work. Where traffic control is required, it shall be the responsibility of Contractor to prepare traffic control plans for the City’s review and implement the traffic control devices as approved by the City. Owner shall also provide access to water hydrants for cleaning, installation and other process related work items requiring water at no charge. Contractor shall procure construction meter from the City for placement on hydrant prior to collecting water for cleaning. B. Cleaning of Sewer Lines – Before lining each segment of sewer pipe, Contractor shall remove all internal debris from the sewer line that could interfere with proper installation of the CIPP. It shall be Contractor’s responsibility remove and legally dispose of debris removed from the sewers during the cleaning operation. C. The contractor shall be solely responsible for preventing service line back-ups during construction. D. Bypassing Sewage – Contractor shall provide for the flow of sewage around the section or sections of pipe designated for repair. Plugging the line at an existing upstream manhole and pumping the flow into a downstream manhole or adjacent system shall be considered an acceptable bypass. The pump(s) and bypass line(s) shall be of adequate capacity to accommodate the sewage flow. The Contractor shall also provide a functional back-up pump of adequate capacity, and a reliable back up power supply. Contractor shall submit a detail of the bypass plan for Engineer’s review prior to starting work on any segment. E. Inspection of Pipelines - Inspection of pipelines shall be performed by experienced, NASSCO PACP certified personnel trained in locating breaks, obstacles and service connections using close circuit television (CCTV) inspection techniques. The pipeline interior shall be carefully inspected to determine the location of any conditions that may prevent proper installation of CIPP. These locations shall be noted and corrected. A videotape and suitable written log for each line section shall be produced and submitted to Engineer for review. F. Line Obstructions - It shall be the responsibility of the Contractor to clear the line of obstructions (at no additional cost to the City) such as solids, roots and Sewer Rehabilitation Program, CIP 18701 13500 - 9 CURED-IN-PLACE-PIPE protruding gaskets, which will prevent or hinder the insertion of CIPP. If pre- installation inspection reveals an obstruction such as a protruding service connection, dropped joint, or a collapse, that cannot be repaired with conventional sewer cleaning equipment, the Contractor shall notify the City immediately. This should be submitted to the City as a Critical Damage Report (CDR). The CDR shall include all adverse conditions from manhole to manhole for the pipe segment in question. The pre-inspection video and report of the deficient segment shall be submitted to the City, along with recommendation from CIPP Contractor for each adverse condition. After reviewing this information, the City will direct the Contractor on how to proceed G. Public Notification - Contractor shall make every effort to maintain sewer service usage throughout the duration of the project. In the event that a connection will be out of service, the longest period of no service shall be 4 hours. A public notification program shall be implemented, and shall as a minimum, require Contractor to be responsible for contacting each home or business connected to the sanitary sewer and informing them of the work to be conducted, and when the sewer will be off-line. Contractor shall also provide written notice to be delivered to each home or business 24-hours prior to the beginning of work being conducted on the section, and a local telephone number of the Contractor they can call to discuss the project or any potential concerns. H. The Contractor shall be responsible for confirming the locations of all branch service connections prior to installing the CIPP. 3.2 INSTALLATION A. CIPP installation shall be in accordance with ASTM F1216, Section 7, or ASTM F1743, Section 6, with the following modifications: 1. Resin Impregnation - The quantity of resin used for liner impregnation shall be sufficient to fill the volume of air voids in the liner with additional allowances for polymerization shrinkage and the loss of resin during installation through cracks and irregularities in the original pipe wall. 2. If a vacuum impregnation process is used, the point of vacuum shall be no further than 25-feet from the point of initial resin introduction. After vacuum in the liner is established, a vacuum point shall be no further than 75-feet from the leading edge of the resin. The leading edge of the resin slug shall be as near to perpendicular to the longitudinal axis of the liner as possible. A roller system shall be used to uniformly distribute the resin throughout the liner. If the Installer uses an alternate method of resin impregnation, the method must produce the equivalent results. Any alternate resin Sewer Rehabilitation Program, CIP 18701 13500 - 10 CURED-IN-PLACE-PIPE impregnation method must be documented to the Owner’s satisfaction that the saturation of the CIPP is sufficient. 3. Delivery, storage and handling of approved materials are the responsibility of the Contractor. The Contractor shall keep them safe from damage and stored with the proper environmental containment as outlined by the manufacturer. No products should be used that have exceeded the designated shelf life as outlined by the manufacturer. Remove damaged products from site. Promptly replace damaged products with new products at no additional cost to the City. 4. Maintain resin impregnated tubes in refrigerated truck trailers at a temperature below 45 degrees F to prevent premature curing. Prior to beginning inversion, no portion of the resin impregnated tubes liner shall be subjected to sunlight or ultraviolet radiation. Resin impregnated tubes with signs of premature curing shall not be installed and shall be removed from the project site. 5. Liner Insertion – The wet out liner shall be positioned in the pipeline using either inversion or a pull-in method. If pulled into place, a power winch should be utilized and care should be exercised not to damage the liner as a result of pull-in friction. The liner should be pulled-in or inverted through an existing manhole or approved access point and fully extend to the next designated manhole or termination point. 6. Temperature gauges shall be placed between the liner and the host pipe’s invert position to monitor the temperatures during the cure cycle. 7. Lubricant shall be used to reduce friction between the host pipe and the liner during the inversion or pulled in process. The lubricant shall be poured into the water in the down-tube or applied directly to the tube or inflation bladder. The lubricant used shall be a non-toxic, oil based product that has no detrimental effects on the tube, heating source and pump system, will not support the growth of bacteria, and will not adversely affect the fluid to be transported. 8. Curing shall be accomplished by utilizing hot water, steam or ultraviolet light in accordance with the manufacturer’s recommended cure schedule. B. POST INSTALLATION VIDEO – Contractor shall provide one copy of the electronic video files on CD, showing the pipe after lining. Video shall be annotated to indicate all restored services. Video shall indicate liner free of visual defects, such as foreign inclusions, dry spots, keel, boat hull, fins, pinholes, wrinkles, and other deformities. Such defects may be cause for rejection, at the City’s discretion, in which case the liner will be removed and replaced by the Contractor at no additional cost to the City. Sewer Rehabilitation Program, CIP 18701 13500 - 11 CURED-IN-PLACE-PIPE C. REINSTATEMENT OF BRANCH CONNECTIONS - It is the intent of these specifications that branch connections be re-opened without excavation, utilizing a remotely controlled cutting device, monitored by a CCTV. The Contractor shall certify a minimum of two complete functional cutters plus key spare components are on the job site before each installation or are in the immediate area of the jobsite and can be quickly obtained. Unless otherwise directed by the Owner or his authorized representative, all laterals will be reinstated. 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. D. PARTIAL CIPP LINERS 1. The partial CIPP liner shall be installed in accordance with ASTM F2599 and same requirements for a full length liner. 2. The saturated tube, along with the inversion bladder shall be inserted into the carrying device and pulled into the host pipe. The pull is complete when the end of the launching device is aligned with the beginning of the section to be repaired. The resin and tube shall be completely protected during the pull such that no resin is lost by contact with manhole walls or pipe. The resin that provides a structural seal shall not contact the pipe until positioned at the point of repair. 3. The installer shall be capable of viewing the beginning of the liner contacting the host pipe verifying the exact placement of the liner. No measuring from a CCTV counter or estimating will be allowed. 4. The tube will be extracted out of the carrying device by controlled air or water pressure. The tube is held tightly in place against the wall of the host pipe by the pressure until the cure is complete. 5. Any service lateral connections covered by the sectional repair shall be restored in accordance with section C above. E. INSPECTION 1. CIPP samples shall be prepared and physical properties tested in accordance with ASTM F1216 or ASTM F1743, Section 8, using either method proposed. The flexural properties must meet or exceed the values listed in Table 1 of the applicable ASTM. 2. Wall thickness of samples shall be determined as described in paragraph 8.1.6 of ASTM F1743. The minimum wall thickness at any point shall not be less than the minimum design wall thickness identified above. Sewer Rehabilitation Program, CIP 18701 13500 - 12 CURED-IN-PLACE-PIPE 3. Visual inspection of the CIPP shall be in accordance with ASTM F1743, Section 8.6. F. CLEAN-UP - Upon acceptance of the installation work and testing, the Contractor shall restore the project area affected by the operations to a condition at least equal to that existing prior to the work. * END OF SECTION 13500 * Sewer Rehabilitation Program, CIP 18701 13600 - 1 MANHOLE REHABILITATION SECTION 13600 – MANHOLE REHABILITATION PART 1 - GENERAL 1.1 SUMMARY A. This specification defines the method and material for the rehabilitation of sanitary sewer manholes, utilizing a spray applied calcium aluminate cementitious structural rehabilitation system. The purpose of this project is to obtain a dense and durable concrete lining that is resistant to biogenic corrosion and biosulfuric acid attack and meets the strength requirements described elsewhere in this specification. The work covered in this specification consists of furnishing all labor, equipment, materials, and supervision necessary to accomplish the rehabilitation as specified. When complete the rehabilitated structure shall: 1. Provide for a uniformly smooth surface of specified thickness. 2. Eliminate sources of inflow/infiltration (I/I). 3. Provide a service life that is supported by documented test analysis. B. IDENTIFICATION OF MANHOLES TO BE REHABILITATED 1. The manholes to be rehabilitated are identified on the Contract Exhibits located in Appendix B. Those manholes that display root intrusion or evidence of infiltration upon visual inspection shall include pressure grouting as part of the rehabilitation process, as further described in this specification. Manholes that do not display root intrusion or evidence of infiltration shall be rehabilitated without inclusion of the pressure grouting process. The estimated quantities for each type of rehabilitation are provided in the bid schedule. 1.2 SUGGESTED SEQUENCE OF WORK A. The Contractor's sequence of operation relative to structural rehabilitation shall include, but not be limited to the following: 1. Remove and dispose of existing ladders and/or steps when corroded. 2. Eliminate all sources of groundwater infiltration and voids in walls. 3. Provide a clean, rough sub-surface sufficiently prepared in accordance with the International Concrete Repair Institute (ICRI) Guideline No. 03732 – Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings, and Polymer Overlays to a degree further defined in Part 3 of these specifications. 4. Rehabilitate all interior surfaces including walls, ceilings, benches and channels, unless otherwise indicated. 5. Application of curing compound to all repaired surfaces. Sewer Rehabilitation Program, CIP 18701 13600 - 2 MANHOLE REHABILITATION 6. All manholes in unpaved areas that are identified for rehabilitation shall be raised so that the top of the manhole frame and cover surface is a minimum 6” above surrounding grade. 7. Install New Manhole Frame and Cover where indicated per City Std. Plan No.’s 801 & 807. 8. Third party testing of lining and other structural rehabilitation materials. 1.3 SUBMITTALS A. Contractor shall furnish detailed and complete data pertaining to the rehabilitation product, surface preparation, curing compound and installation. B. Work Plan. The work plan at a minimum shall include details of the surface preparation, how operating air pressure is kept uniform to ensure adequate nozzle velocity, uniform flow of product to nozzle, regulate water content so that applied materials consistently achieve proper compaction. The work plan shall further demonstrate that all spray application operators and foreman each have a minimum of 2 years of experience with application of Sewpercoat PG or equal product. C. Safety plan. It is the contractor's responsibility to comply with OSHA standards and all regulations pertaining to the work including confined space entry. Contractor shall provide the necessary training and take the necessary measures to provide a safe working environment for workers as well as the public. D. Manufacturer’s ISO 9001 certificate and supporting documentation. E. Certified test reports and certificates. 1.4 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and other technical specifications as they apply to this Section. B. ASTM C109 – Standard Test Method for Compressive Strength of hydraulic Cement Mortars C. ASTM C293 – Standard Test Method for Flexural Strength of Concrete D. ASTM C321 – Standard Test Method for Bond Strength of Chemical-Grout Mortars E. ASTM C496 – Standard Test Method for Splitting Tensile Strength Sewer Rehabilitation Program, CIP 18701 13600 - 3 MANHOLE REHABILITATION F. ASTM C596 – Standard Test Method for Drying Shrinkage of Mortar Containing Hydraulic Cement G. ASTM C597B – Standard Test Method for Pulse Velocity Through Concrete H. ASTM C666 – Standard Test Method for Resistance of Concrete Rapid Freezing I. ASTM C882 – Standard Test Method for Bond Strength of Epoxy-Resin Systems J. ACI RAP-3 – Spall Repair by low Pressure Spraying K. ACI 546R (Chapter 2) - Concrete Surface Repair Using Mortar 1.5 SUMMARY A. Section Includes: 1. Prepackaged Mortar Mix Properties 2. Sampling and Testing Requirements 3. Qualifications of Work Crew 4. Surface Preparation and Mortar Application Procedures 5. Infiltration Remediation 6. Curing Sewer Rehabilitation Program, CIP 18701 13600 - 4 MANHOLE REHABILITATION PART 2 - PRODUCTS 2.1 LINING MATERIALS A. Lining material furnished under this specification shall be a prepackaged mortar mix, including all cement, aggregates, and any required additives. It is the intent of this specification that the Contractor only be required to add the proper amount of potable water so as to produce concrete suitable for spray application. Under no circumstances, shall Contractor add Portland cement, other aggregates, or any admixtures whatsoever to the pre-packaged lining material. Typical bag weights shall not be less than 65 lbs. and shall be identical for all material furnished on this project. B. The chemical composition of the cement portion as well as the aggregates of the mortar mix shall be as follows: Al2O3 CaO FeO + Fe2O3 SiO2 40-46% 34-40% 9-15% 4-9% C. The properties of the mortar mix shall meet the following: Compressive Strength per ASTM C109 >5,500 PSI 24 Hours after mixing Flexural Strength per ASTM C293 >1,300 PSI 24 Hours after mixing Splitting Tensile Strength per ASTM C496 >900 PSI - Bond Strength by Slant Shear per ASTM C882 >2,300 PSI At 28 Days Shrinkage at 28 Days per ASTM C596 <0.08% cured @ 90% Relative Humidity at 28 days D. The lining material mortar mix shall be “SewperCoat PG” as manufactured by Kerneos Inc. – Chesapeake, Virginia or Approved Equal. E. The lining material mortar mix must have at least seven (7) years of successful performance in similar applications and be supplied by an ISO 9001 certified manufacturer. F. In addition, the lining material mortar mix shall be designed to withstand long- term exposure to a bacterially corrosive hydrogen sulfide environment that may Sewer Rehabilitation Program, CIP 18701 13600 - 5 MANHOLE REHABILITATION be expected to produce a pH of 1 on normal Portland cement based concrete or typical brick and mortar surfaces. G. Water used in mixing shall be fresh, clean, potable water, free from injurious amounts of oil, acid, alkali, vegetable, sewage and/or organic matter. Water shall be considered as weighing 8.32 pounds per gallon. H. Lining material mortar mix shall be stored with adequate provisions for the prevention of absorption of moisture. It shall be stored in a manner that will permit easy access for inspection and identification of each shipment. PART 3 - EXECUTION 3.1 SAMPLING AND TESTING A. A recognized independent testing laboratory shall test mortar materials used on the project. B. The cost of sampling and testing of the mortar mix during placement and the surface to which it is applied shall be borne by the Contractor. Other testing required showing conformance with these specifications shall also be the responsibility of the Contractor. C. Any materials failing to meet the requirements of these specifications shall not be incorporated into the Work. If the materials have already been installed when it is determined that they don’t meet these specifications, then the subject materials shall be removed and the work repeated with materials that meet the specifications. 3.2 QUALIFICATIONS OF THE WORK CREW A. The manufacturer shall maintain a listing of competent contractors that have demonstrated requisite skill and training to be qualified applicators of their materials. B. Prior to project commencement, Contractor must verify that all Contractor’s work crew personnel have performed satisfactory work in similar capacities elsewhere for a sufficient period of time to be fully qualified to properly perform the work in accordance with the requirements of the related specifications. C. Foreman shall have at least 4 years of experience with similar work and project conditions. D. Nozzle and spray equipment operators shall be qualified by having had similar work experience. Sewer Rehabilitation Program, CIP 18701 13600 - 6 MANHOLE REHABILITATION E. Work Crew responsibilities prior to application of lining material shall include the following: 1. Surface preparation in accordance with section 3.4. 2. Ensure the operating air pressure is uniform and provides adequate nozzle velocity for proper compaction. 3. Continuously regulate the water content so that the applied materials consistently achieve proper compaction with a low percentage of rebound and no visible “sag”. 4. Ensure that the installation equipment nozzle is held at the proper distance away from and as nearly perpendicular to the prepared sub- surface as the working conditions will permit to secure maximum material compaction with minimum rebound and no visible “sag”. 5. Follow a sequence routine that will fill corners with adequately compacted material applied at a maximum practicable layer thickness. 6. Determine necessary operating procedures for placement in confined spaces, extended distances or around unusual obstructions where placement velocities and mix consistency may need to be adjusted. 7. Direct the crew as to when to start and stop the flow of materials during installation and to immediately stop all work when material is not arriving uniformly at the nozzle. 8. Ensure that slough pockets are removed and prepared for installation of replacement material. 9. Bring the installed materials to established finished elevations in a neat and timely manner and within established tolerances. F. Applicator’s job foreman shall operate the mixing/placing equipment and direct the work of mixing crew personnel. Applicator’s work crew shall also maintain proper line pressures throughout the mixing/placing equipment to ensure the necessary consistent nozzle velocity. Applicator’s work crew shall further see that all material fed to the nozzle is uniformly fed through this equipment. Sewer Rehabilitation Program, CIP 18701 13600 - 7 MANHOLE REHABILITATION 3.3 EQUIPMENT - Equipment shall be of spray type and approved by the material manufacturer. Alternate equipment may be utilized provided it meets the performance requirements of the specification. All equipment must be in good condition and fully functional. 3.4 SURFACE PREPARATION A. Sub-surfaces shall be cleaned and made free of laitance, loose material, residue and all existing coating and lining materials. Surface preparation shall meet the requirements of American Concrete Institute (ACI) RAP-3 “Spall Repair by Low Pressure Spraying” and ACI 546R “Concrete Repair Guide”, chapter 2. B. Sub-surfaces shall be thoroughly saturated with water prior to the application of the lining materials. In no instance shall shotcrete be applied in an area where running water exists. It is the intent of this specification that the existing surface be saturated but free of any running water just prior to installation, otherwise known as “saturated surface dry condition” (SSD). To achieve this condition it may be necessary to presoak the sub-surface for at least 24 hours. 3.5 OPERATIONS A. The Contractor shall provide all equipment necessary to individually gauge, control, and monitor the actual amounts of all component materials necessary to complete the lining installation. The type of equipment and methods used to gauge, control, and monitor component materials shall be subject to approval by the Engineer. B. All lining materials shall be thoroughly mixed by mechanical means to ensure all agglomerated particles are reduced to original size or removed prior to placement into the application equipment (i.e. the hopper). Each batch of material should be entirely discharged before recharging with fresh material. Mixing equipment shall be cleaned at regular intervals to remove all adherent materials. C. The addition of water to the mix shall be in strict accordance with the Manufacturer’s recommendations. D. Re-mixing or tempering shall not be permitted. Rebound materials shall not be reused. 3.6 PROTECTION OF ADJACENT SURFACES - During progress of the work, adjacent areas or grounds which may be discolored, stained or otherwise damaged by dust and rebound material, shall be adequately protected. If spills Sewer Rehabilitation Program, CIP 18701 13600 - 8 MANHOLE REHABILITATION or overspray occur, the area shall be immediately cleaned by scraping, brushing or washing. 3.7 CURING A. Several layers of liquid membrane curing compound shall be applied to all surfaces and shall meet the requirements of ASTM C309. Curing compound shall be approval by the Engineer prior to use. B. Moist curing may also be used in lieu of curing compound. If moist curing is selected, it should be implemented just after the notice of uniform heat generation of the installed lining. Moist curing can consist of the use of soaker hoses, water sprinklers, or vapor/misting machines to achieve a 100% humid moisture condition. Regardless of delivery method, moist curing shall continue for a minimum of 18 hours. 3.8 INFILTRATION REMEDIATION A. If infiltration is observed or voids are present after surface preparation is complete, a rapid setting crystalline enhanced hydraulic cement repair mortar product specifically formulated for infiltration control shall be used to stop minor infiltration flows and fill voids in accordance with the manufacturer's recommendations. The material shall meet the following strength requirements: Compressive Strength per ASTM C597B 600-PSI 1,000-PSI 24-Hours 7-Days Bond Strength per ASTM C321 30-PSI 80-PSI 1-Hour 24-Hours B. All manholes displaying evidence of minor infiltration upon visual inspection in the presence of the City inspector shall be repaired by filling space between joints, cracks, voids and other structural deficiencies with repair mortar. Repair mortar shall be Thoroc Plug, Octocrete, Burke Plug or Engineer approved equal and shall be installed in accordance with the manufacturer’s published instructions. C. All manholes displaying evidence of heavy infiltration upon visual inspection in the presence of the City inspector shall be sealed by pressure grouting prior to installation of the Sewpercoat lining. The material for pressure grouting shall be Avanti A-220, DeNeef or Engineer approved equal installed in accordance with the manufacturer's published instructions. Sewer Rehabilitation Program, CIP 18701 13600 - 9 MANHOLE REHABILITATION D. If steel reinforcement is exposed and corroded, it shall be cleaned by brushing or wet grit blasting until all corrosion is removed prior to application of repair mortar. E. All materials, labor, equipment, and incidentals required to replace missing concrete or correct infiltration conditions will be considered incidental to rehabilitation and no additional compensation will be made. 3.9 APPLICATION OF LINING A. Lining material shall not be applied to a frozen surface or to a surface that may freeze within 24 hours of application. Frozen conditions shall be defined as ambient temperatures of 32 degrees Fahrenheit or below. B. Sequence of application may be from bottom to top or vice versa and rebound shall be properly removed. C. Application shall be from an angle as nearly perpendicular to the surface as practicable, with the nozzle held at least 1 foot from the working sub-surface (except in confined control). If the flow of material at the nozzle is not uniform and slugs, sand spots, or wet sloughs result, the nozzle operator shall direct the nozzle away from the work until the faulty conditions are corrected. Such defects shall be removed and replaced as the work progresses. D. Application shall be suspended if: 1. Air velocity separates the cement from the aggregate at the nozzle. 2. Ambient temperature approaches freezing and the newly placed lining cannot be protected and insulated. E. The time interval between successive layers of material application must be sufficient to allow “tackiness” to develop but not final set. If final set does occur, this surface shall be prepared as in the case of initial application, which is described above. F. Construction joints within a manhole shall be avoided. In the event a construction joint is necessary and approved by the Engineer, it shall be sloped off to a thin, clean, regular edge, at a 45-degree angle. Prior to placement of the adjoining materials, the sloped portion and adjacent applied material shall be thoroughly cleaned as necessary, then moistened and scoured with an air jet. G. The nozzle operator shall bring the material to an even plane and to well- formed corners. Sewer Rehabilitation Program, CIP 18701 13600 - 10 MANHOLE REHABILITATION H. After the body coat has been placed, the surface shall be trued with a thin-edge screed to remove high areas and expose low areas. Low areas shall be properly filled with additional material to insure a true, flat surface. I. The minimum thickness of concrete lining shall be a ¾ inch cover over all surfaces. * END OF SECTION 13600 * Annual Sewer Rehabilitation Program, CIP 18701 13700 - 1 SERVICE LATERAL CONNECTION REHABILITATION SECTION 13700 – SERVICE LATERAL CONNECTION REHABILITATION PART 1 - GENERAL 1.1 INTENT A. It is the intent of this portion of the specification to provide for the rehabilitation of service lateral connections (SLC) to rehabilitated sewer lines, without excavation, by installation and ultraviolet (UV) light curing of a resin- impregnated, flexible fiberglass insert with sealing epoxy element in the form of a tube and top hat that will be installed into the existing service lateral utilizing a pressure apparatus and ultraviolet light curing device positioned in the mainline pipe. Service lateral connections may be a combination of tee's, wye's or break- in taps of varying sized and angle from 30 to 90 degrees and may include over- cut lateral openings, pilot holes or defects in relined sewer pipe. The resin shall be rapidly cured to transform the flexible insert into a hard, impermeable top hat seal around and in the lateral connection. The SLC product shall extend from the mainline into the lateral connection a minimum distance of 2 feet, in a continuous tight fitting, watertight pipe within-a-pipe to eliminate ground water leakage and future root growth at the lateral to mainline connection. SLC product system shall be compatible with the mainline liner. If, within the warranty period, the SLC product installed in the sewer system is not acceptable due to leakage or any other defects, the contractor shall repair or replace the affected portion at no cost to the City of San Juan Capistrano. 1.2 RELATED DOCUMENTS A. This specification references standards from the American Society for Testing and Materials that are hereby made a part of these specifications by reference: 1. ASTM D543 – Standard Practices for Evaluating the Resistance of Plastics to Chemical Reagents. 2. ASTM F1216 – Standard Practice for Rehabilitation of Existing Pipelines and Conduits by the Inversion and Curing of a Resin Impregnated Tube. 3. ASTM D3681 – Standard Test Method for Chemical Resistance of Fiberglass (Glass-Fiber-Reinforced Thermosetting Resin) Pipe in a Deflected Condition. 4. ASTM D2990-09 – Standard Test Methods for Tensile, Compressive, and Flexural Creep and Creep Rupture of Plastics and Electrical Insulating Materials. Annual Sewer Rehabilitation Program, CIP 18701 13700 - 2 SERVICE LATERAL CONNECTION REHABILITATION 5. ASTM D790 – Standard Test Methods for Flexural Properties of Reinforced and Unreinforced Plastics. 6. ASTM D5813 – Standard Specifications for Cured-In-Place Thermosetting Resin Sewer Piping Systems. 7. ASTM D578 - Standard Specifications for Glass Fiber Strands. 8. ASTM D638 – Standard Test Methods for Tensile Properties of Plastics. 9. ASTM D1600 – Standard Terminology for Abbreviated Terms Relating to Plastics. B. Reference is further made to National Association of Sewer Service Companies (NASSCO) Standard: Recommended Specification for Sewer Collection Systems Rehabilitation. 1.3 QUALIFICATIONS A. The SLC rehabilitation contractor must have a minimum of a two (2) year history of satisfactory performance with a minimum of 2,000 Top Hat lateral repair installations of similar size and configuration as proposed in this project. In addition, the onsite Superintendent must have installed over 1,000 Top Hat lateral repairs of similar condition and have a minimum of 2 years of CIPP industry experience. B. The sewer repairs specified herein are intended to have a 50-year design life. In order to minimize the Owner’s risk, only proven products with substantial successful long-term track records will be approved. 1.4 SUBMITTALS – As a minimum, Contractor shall submit the following for review: A. Resin. Long term test creep data confirming the resin system’s 50 year design life in accordance with ASTM D2990. Chemical Resistance per ASTM F 1216. Certificate of Compliance with ASTM F 1216 B. Tube. Certificate of Compliance with ASTM F1216. If glass fiber reinforcement is used, CIPP strain Corrosion testing data in accordance with ASTM D3681. C. CIPP wall thickness design calculations (for lateral liner) in accordance with ASTM F1216. D. The Contractor shall provide the inversion pressures necessary for proper insertion and tube installation. The tube manufacturer shall provide the minimum pressure required to hold the tube tight against the existing host pipe, Annual Sewer Rehabilitation Program, CIP 18701 13700 - 3 SERVICE LATERAL CONNECTION REHABILITATION and the maximum allowable pressure that will not damage the tube. Forces or pressures shall be limited so the tube is not stretched longitudinally by more than 5% of the original length. E. The contractor or subcontractor performing the lateral lining work shall provide a list of references, including Owner Name, Contact Name with phone number, start and completion dates and Quantity of Laterals Lined, with the CIPP Lateral Lining system used for that specific project provided, verifying compliance with the qualifications indicated in section 1.3 above. F. License or Certification that the contractor is approved to install the proposed product. G. Post Construction CCTV Videos, Reports and Photographs which clearly show the lateral repairs 1.5 BIDDER’S INSPECTION – Bidder shall examine pre-construction CCTV video files of sewers and become familiar with the existing sewer conditions prior to submitting a bid. Videos will be made available for review on a web based account for rapid sharing. Refer to the Notice Inviting Bids for more information. PART 2 - PRODUCTS 2.1 MATERIALS A. The finished SLC product shall be an ECR (E-glass corrosion resistant) fiberglass laminate impregnated with a UV light reactive polyester resin which when cured is chemically resistant to domestic sewage over the expected lifetime of the rehabilitated pipe. B. The carrier material for the tubes shall be of fibrous absorbent composition tailored to achieve the following: 1. Allow the migration of resin from its internal structure by compressing to a thickness of less than 90% of its uncompressed thickness under a pressure of 1psi. 2. The carrier material must consist of non-degradable fibers such as polyester or polypropylene or corrosion resistant fiberglass. The carrier may use stitched or glued joints of material with sufficient strength to comply with the following minimum requirements: Table 1 CIPP Initial Structural Properties Annual Sewer Rehabilitation Program, CIP 18701 13700 - 4 SERVICE LATERAL CONNECTION REHABILITATION 3. The material must have an abrasion resistant, chemically resistant, fully bonded coated surface in the lateral portion to ensure that on curing a smooth surface free from blemishes, pinholes or loose non wetted fibers. 4. Where fiberglass is used, a surface veil or a layer of felt must be used to prevent osmosis or wicking of the strands. 5. PET resins, resin filters, resin additives, and resin enhancement agents are prohibited. Only neat resins are acceptable. Old resins and reworked resins are prohibited, regardless of whether or not they are mixed with new resin. 6. Proven resistance to the municipal wastewater environment that may comprise, as a minimum, all of the following factors: a. Immersion in septic sewage at temperatures up to 75 degrees F. b. Exposure in hydrogen sulfide gas from septic sewage at temperatures up to 75 degrees F. c. Resistance to ultra-violet light (sunlight) at any stage prior to installation. d. Solvent free epoxy, polyester, silicate, and vinyl ester resins are acceptable. e. Shall not use silicones, stereates, or natural waxes that would adversely affect the adhesive properties or any other chemical or physical properties of the CIPP liner. C. The SLC product shall be compatible with the lining system utilized for the sewer main. D. The flexible fiberglass top hat tube insert shall be fabricated to a size that when installed will key into the internal surface irregularities of the lateral joint and neatly fit tight to the internal circumference of the lateral. The top hat tube shall be a laminate made of non-woven fiberglass materials (as outlined above) that allow for circumferential stretching and angular alignment with the lateral pipe connection geometry during insertion. E. The insert laminate shall seal to the inside wall of the sewer main a minimum of 3 inches around the lateral opening and to the lateral pipe wall and12 inches up into the lateral pipe from the main. Table 1 CIPP Initial Structural Properties (ASTM F1216) Property ASTM Method Minimum Value Tensile Strength D638 3,000 psi Flexural Strength D790 4,500 psi Modulus of Elasticity D790 250,000 psi Annual Sewer Rehabilitation Program, CIP 18701 13700 - 5 SERVICE LATERAL CONNECTION REHABILITATION F. Unless otherwise specified, the installer shall furnish a specially formulated polyester resin and catalyst system compatible with the SLC process that provides cured physical strength equal to or greater than that of the main line CIPP liner. G. A secondary epoxy sealing component shall be used to form a sealing bond between the SLC product and the host lateral and sewer main CIPP liner. 2.2 PHYSICAL PROPERTIES A. The cured SLC shall have a minimum Flexural Modulus of Elasticity equal to 800,000 psi in accordance with ASTM D790. B. The top hat service lateral connection (SLC) repair system fiberglass and resin composite shall have the minimum physical properties given below and in accordance with the guidelines in the appendix of ASTM F1216. 1. Design Life: 50 Years. 2. Ovality: 2% 3. Pipe Condition: Fully deteriorated 4. External Water: ground surface 5. Flexural Strength: 4,500 psi 6. Short Term Flexural Modulus: 250,000 psi 7. Reduction Factor: 50% 8. Long Term Flexural Modulus: 125,000 psi 9. k (enhancement Factor): 7 10. Soil Modules: 1,000 psi 11. Soil Density: 120 pcf 12. Highway Live Load: AASHTO HS20-44 13. Safety Factor: 2 minimum 14. Min. Thickness 3 mm 15. If calculations require thicker wall, round to the next higher multiple of 0.5 mm. C. Any layers of the tube that are not saturated with resin prior to insertion into the existing host pipe shall not be included in the required design structural CIPP wall thickness. Annual Sewer Rehabilitation Program, CIP 18701 13700 - 6 SERVICE LATERAL CONNECTION REHABILITATION 2.3 Delivery, Storage and Handling. Delivery, storage and handling of approved products are the responsibility of the Contractor. The Contractor shall keep them safe from damage and stored with the proper environmental containment as outlined by the manufacturer. No products should be used that have exceeded the designated shelf life as outlined by the manufacturer. Remove damaged products from site. Promptly replace damaged products with new products at no additional cost to the City of San Juan Capistrano. PART 3 - EXECUTION 3.1 LINE PREPARATION A. Contractor shall video inspect the service lateral immediately prior to the repairs of the lateral and connection. The Contractor shall use a self-leveling camera to determine the structural condition of the service lateral. Waste product build up, hard scale, roots, lateral cutting debris, resin slugs or any other material that interferes with proper installation of the top hat repair must be removed using high pressure water jetting or in line cutters. B. The section of lateral pipe to be lined must be free of debris, obstructions, scale, or any other material that reduces the effective diameter of the pipe. C. Break in connection and/or lateral pipe protruding into the mains shall be ground back to no more than a 1/8 inch protrusion into the mainline. D. Built up deposits on the main and lateral pipe walls shall be removed. The removal shall reach at least one foot beyond the SLC repair to allow the bladder to inflate tightly against the pipe walls ensuring a smooth transition from the SLC repair to the existing pipe wall. E. The contractor shall notify the Engineer immediately if the inspection reveals an obstruction or if other conditions exists that will interfere with the proper installation of the SLC repair. F. In relined pipes, the lateral must be opened 95 percent or more and edges finished without “teeth”. Over-cuts shall not exceed one inch beyond the internal diameter of the lateral. The top hat contractor is responsible for coordinating with the CIPP contractor (should they be different entities) for proper opening of service lateral connections. G. The contractor shall be responsible for preparation and distribution of public notification flyer that explains the repair operation, when it will be performed, how long it will take, and what the homeowner needs to do to help facilitate installation of the SLC repair. SLC repair operation shall not require a disruption of flow that exceeds four (4) hours. Coordinate homeowner notification with the City of San Juan Capistrano. Annual Sewer Rehabilitation Program, CIP 18701 13700 - 7 SERVICE LATERAL CONNECTION REHABILITATION H. The SLC repair contractor is responsible for cleaning the main sewer pipe and lateral as required to facilitate the repair, and as a minimum within one foot of the work area only. Remaining portions of the main sewer pipe will be cleaned by the main sewer pipe CIPP contractor. 3.2 INSTALLATION A. The resin impregnated SLC product shall be loaded on the applicator apparatus, attached to a robotic manipulator device and positioned in the mainline pipe at the service connection that is to be rehabilitated. The robotic device, in conjunction with a television camera, will be used to align the SLC repair product with the service connection opening. Air pressure, supplied to the applicator through an air hose, shall be used to insert the resin impregnated connection repair product into the lateral pipe. The inserted product will then be inspected using a TV camera to confirm the SLC product is correctly positioned and centered in the lateral opening prior to curing. The insertion pressure will be adjusted to fully deploy the SLC product into the lateral connection and hold it tightly to the main and lateral pipe walls. B. The pressure apparatus shall include a bladder of sufficient length in both the main and lateral line such that the inflated bladder extends beyond the ends of both the lateral tube and main line brim segments of the SLC product. The pressure apparatus shall press the end edges flat against the internal pipe wall thus forming a smooth transition from SLC product to pipe diameters without a step, ridge or gap between the SLC product and the inner diameter of the lateral and mainline pipe. C. After insertion is completed, recommended pressure must be maintained on the impregnated SLC product for the duration of the UV light curing process. D. The finished SLC repair shall be free of dry spots, lifts and delamination. The installed SLC product (top hat) should not inhibit the post installation video inspection, using a closed circuit television camera, of the mainline or service lateral pipes or future pipe cleaning operations. E. After the work is completed, the contractor will provide the City of San Juan Capistrano with the post installation CCTV video, report and photographs identifying the location and showing the completed work and restored condition of each top hat repair. F. During the warranty period, any defects with the SLC repairs shall be corrected at the contractor’s expense in a manner acceptable to the City of San Juan Capistrano. Annual Sewer Rehabilitation Program, CIP 18701 13700 - 8 SERVICE LATERAL CONNECTION REHABILITATION 3.3 INSPECTION A. The finished liner shall be free from visual defects such as foreign inclusions, dry spots, pinholes, wrinkles and other deformities. B. The contractor shall inspect each installation visually by CCTV. No infiltration of groundwater shall be observed. The repair product shall be inspected closely for excessive wrinkling, exposed unwetted fibers, pinhole leaks and infiltration around the terminations. The pre and post connection CCTV videos, reports and photographs shall become the property of the City of San Juan Capistrano. 3.4 CLEANUP A. The Contractor shall restore the project area affected by the operations to a condition at least equal to that existing prior to the work. During the warranty period, any defects with the SLC repair that affect the performance or cleaning of the lateral connection shall be repaired at the contractor’s expense in a manner acceptable to the City of San Juan Capistrano. * END OF SECTION 13700 *