Project #324 - Technical Specs - 2019-04-29
TECHNICAL SPECIFICATIONS
SEWER MANHOLE REHABILITATION 2019 (PHASE 1)
Project No. 324
GENERAL SPECIFICATIONS
All construction including materials, testing, and installation shall conform to the following
specifications:
1.1 Costa Mesa Sanitary District “Standard Plans and Specifications for the Construction
of Sanitary Sewers” as last revised.
1.2 Standard Specifications for Public Works Construction (SSPWC) latest edition also
referred to as the “Greenbook”.
1.3 American Society of Test and Materials (ASTM) latest edition.
TECHNICAL SPECIFICATIONS FOR MANHOLE STRUCTURAL LINER
Contractor shall furnish all labor, materials, and equipment for the rehabilitation of the
existing manholes with cured-in-place composite liner system per attached technical
specifications. The liner system shall be Triplex Liner System, Alternative Liner System, or
approved equal.
The liner for this project shall be Triplex-6800 series OR AltLiner Model CIPMTM 106
OR approved equal since the manholes have serious deterioration, infiltration and/or
exfiltration problems.
CMSD Project No. 324 Special Provisions – 2 of 11
TRIPLEX LINER SYSTEM
PART 1 GENERAL
1.1 PRODUCT DESCRIPTION
A. The Triplex Liner System is a cured-in-place structural liner designed for use as a non-
porous, multi-layer structural system for rehabilitation for structures such as manholes,
pump stations, wet wells, vaults, storage tanks, large diameter pipe, and corrugated
culvert pipe. It provides an impervious water and sewer gas resistant membrane,
layered between layers of structural fiberglass or polyester fiber. Therefore, the liner
system is ideal for correcting H2S gas deterioration, infiltration and exfiltration
problems in structures of most any shape or size.
B. This waterproof liner system completely seals off infiltration and exfiltration. The
epoxy resins used in conjunction with the fiberglass liner fabric are resistant to gases
and chemicals typically encountered in domestic sewer systems. The liner permanently
adheres to wet or dry surfaces of brick, concrete, PVC, and ductile iron; it prevents
further deterioration, infiltration, and exfiltration, while providing structural
reinforcement to the existing structure, and provides a chemical and sewer gas
resistant protective lining system. Other epoxy or vinyl-ester resins may also be used
in conjunction with the Triplex Liner for special chemical and industrial applications.
C. The Triplex Liner System is manufactured in four (4) standard liner weights that are
designed for varying depths and varying structural conditions. These four liner designs
provide the end-user with the right choice for fulfilling lining needs ranging from
preventive maintenance to very serious structural problems with infiltration and/or ex-
filtration.
D. Each liner is a type that allows rehabilitation of concentric, eccentric or flat top
structures without removing the ring top section or corbel. This minimizes traffic
disruption and eliminates the need for road repairs. All liner material and components
are custom fabricated at the McNeil Technologies LLC, manufacturing facility to fit the
size and shape of each individual structure. Structure measurements are taken and liners
are manufactured prior to commencement of the liner installation to minimize the on-
site field time required for the liner installation.
PART 2 PRODUCTS
2.1 MATERIALS
Triplex-4400 Liner - Multiple layer composite with non-porous membrane mechanically bonded between the layers of polyester fiber or 2 layers of 12 oz. PSY woven roving fiberglass, saturated with 100% solids epoxy, cured -in- place, and bonded to the existing structure.
Triplex-5600 Liner - Multiple structural fiberglass layers with a non-porous membrane
bonded between the layers of fiberglass, with a total fabric weight of 56 oz. per square yard,
saturated with 100% solids epoxy, cured-in-place, and bonded to the existing structure.
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Triplex-6800 Liner - Multiple structural fiberglass layers with a non-porous membrane bonded between the layers of fiberglass, with a total fabric weight of 68 oz. per square yard, saturated with 100% solids epoxy, cured-in-place, and bonded to the existing structure. Triplex-11600 Liner - Multiple structural fiberglass layers with a non-porous membrane bonded between the layers of fiberglass, with a total fabric weight of 116 oz. per square yard, saturated with 100% solids epoxy, cured-in- place, and bonded to the existing structure.
2.2 LINER SYSTEM DETAILS
The 4400 series is a three-layered composite system. The 4400 is designed for structures up to
8’ in depth. Layer #1 is non-woven polyester or 12-oz. structural fiberglass, impregnated with a
modified epoxy resin and bonded to the existing substructure. Layer #2 is a non-porous
membrane of special synthetic materials mechanically bonded between layer #1 and layer #3.
Layer #3 consists of non-woven polyester or 12-oz. structural fiberglass that is saturated with
epoxy resins, forming a smooth interior wall to the host structure.
The 5600 series is a three-layered composite system with a total pre-saturated fabric weight of
56-ozs. per square yard. The 5600 is designed for structures up to 29’ in depth. Layer #1 is 18-oz.
structural fiberglass impregnated with a modified epoxy resin and bonded to the existing
substructure. Layer #2 is a 20-oz. non-porous membrane of special synthetic materials bonded to
layer #1 and layer #3. Layer #3 consists of 18-oz. structural fiberglass saturated with epoxy and
bonded to the nonporous membrane, forming a smooth interior wall to the host structure.
The 6800 series is a three-layered composite system with a total pre-saturated fabric weight of
68-ozs. per square yard. The 6800 is typically designed for structures up to 38’ in depth.
Layer #1 is 24-oz. structural fiberglass impregnated with a modified epoxy resin and bonded to
the existing substructure. Layer #2 is a 20-oz. non-porous membrane of special synthetic
materials bonded to layer #1 and layer #3. Layer #3 consists of 24 -oz. structural fiberglass
saturated with epoxy and bonded to the nonporous membrane, forming a smooth interior wall
to the host structure. For structures deeper than 24 feet, or for structures experiences heavy
infiltration, additional layer(s) of fiberglass may be added as needed.
The 11600 series is a three-component composite system with a total pre-saturated fabric
weight of 116-ozs. per square yard. The 11600 series is designed for culvert pipe and manhole
type structures up to 55’ in depth. Component #1 is (2) 24-oz. structural fiberglass layers
impregnated with a modified epoxy resin and bonded to the existing substructure. Component
#2 is a 20-oz. non-porous membrane of special synthetic materials bonded to layer #1 and
layer #3. Component #3 consists of (2) 24-oz. structural fiberglass layers saturated with
epoxy and bonded to the nonporous membrane, forming a smooth interior wall to the host
structure. Additional layer(s) of fiberglass may be added as needed.
2.3 RESIN FOR WASTEWATER SERVICE
A. The standard impregnating resin for typical domestic wastewater sewer system liners is a modified Polyamide Bisphenol “A” Epichlorodhydrin system that is field applied. After the resin is applied, the liner is lowered into the manhole where, in most cases, it is cured in place with a temperature inversion system of air pressure and steam heat injection. Most liners are cured within two hours and become a structural monolithic wall bonded to the host structure. Other chemical and industrial applications may require alternate resin system depending on the site conditions and chemicals present
CMSD Project No. 324 Special Provisions – 4 of 11
in the structures. In these cases the Owner shall supply an analytical report of chemicals present to McNeil Technologies LLC. The resin system used in these cases is determined on a case-by- case basis.
2.4 LINER SIZE
A. Each liner is custom fabricated to fit the individual structure. There is no standard configuration in manholes and many other structures; therefore, exact measurements must be completed and submitted prior to manufacturing each liner. McNeil Technologies LLC provides diagrams for location, configuration, measurements, site & structure conditions, notes and observations.
2.5 APPLICABLE MANUFACTURERS
A. Products specified by named manufacturers are specified as a standard of
quality.
1. McNeil Technologies LLC
404 Stewart Street, Bonifay, Florida 32425
Attn: Ron McNeil
Phone: (850) 687-9696
2. Approved equal.
2.6 ACCEPTABLE LINER INSTALLERS
A. Certified installer: Ayala Engineering Inc.
8482 East Meadowridge Street
Anaheim, CA 92808
Attn: Ricardo Ayala
Phone: (714) 823-7179
B. Approved equal.
PART 3 EXECUTION
3.1 INSTALLATION PROCESS
A. Cleaning: All surfaces of the host structure are to be cleaned with a high-pressure
hydro-jet sprayer with an operating pressure of at least 4,000-psi. After pressure
cleaning, surface may be cleaned with degreaser or other solvents, as needed, in order to
remove any film or residue on the surface. Structure shall then be pressure rinsed with
water. B. Final Preparation: All incoming laterals and main truck line openings shall be properly trimmed and grouted with hydraulic or Portland Type II Cement, forming a filet between the structure wall and each pipe. All inlet and outlet pipes should be trimmed so they do not extend into the structure more than two inches. Such application of grout shall extend at least six inches from the outlet onto the wall area. Manhole steps shall be removed flush to within ½” of the structure wall. Any remaining protrusion shall be grouted over to provide smooth surface for the liner.
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C. Benches, walls, and floors shall be repaired or refinished as appropriate, using chemical
grout, hydraulic cement or Portland type II cement. Bench areas and floors shall be
lined with Triplex Liner System materials saturated with the epoxy resin and placed in
the bottom, extending approximately 6 inches up the wall section, so as to overlap with
the liner wall section.
3.2 MANHOLE LINER INSTALLATION
A. Once the liner is fully saturated with resin at the job site, it shall be lowered into the structure to the pre-marked position at the cover seat of the structure entrance. The liner shall form a monolithic structure permanently connecting the ring & cover seat to the chimney, corbel, walls, and benches. Unless otherwise required, the liner will end at, but include, the bench. In cases where invert channel lining is required, the sewage flow must be stopped for a minimum period of 3 hours, and should be a separate cost item.
B. Normal installation procedures do not require the restricting or bypassing of the main
trunk line in manholes where the sewage flow is contained within the channels, and
channel lining is not required.
C. In cases where channel is required to be lined, the same process may be used as on the
bench area however, the sewage flow must be stopped. Channels may also be lined with
a hand lay-up method using EPOSealTM fast setting mastic and fiberglass. Using the
hand lay-up method, the channel shall be dry and free of infiltration of groundwater. The
channel will receive not less than 1 24-oz structural fiberglass layer along with
structural fiber reinforced epoxy mastic. Once the channel lining is cured, additional
layers may be applied as needed. If channel lining is required it shall be specifically noted
in the liner proposal or the client’s quotation request.
D. The Triplex Liner for manholes shall be pressurized with air or water, and cured with steam, ambient or heated air, or ambient or heated water. Most typical Triplex manhole liner installations will be pressurized at 432-1,008 lbs. per square foot, depending on the condition of the structure and t he amount of hydrostatic pressure from incoming infiltration.
3.3 CURING PROCESS
A. Once positioned inside the structure, the liner is pressurized with air or water. It is
then cured with steam, ambient or heated air, or ambient or heated water. Most typical
installations are heated by a temperature inversion system of pressurization with
steam injection and a high velocity hot air column. This creates a steam/convection
oven atmosphere which brings the liner temperature to approximately 150 to 190 F.
The liner is heated for approximately one to three hours. The actual curing time will
generally be based on the size of the structure. Regardless of curing process, the
Triplex Liner System will be fully covered under Triplex warranty.
B. Upon completion of the liner curing process, the inflation bladder shall be removed, all
lines reopened. and the excess liner cut off at the manhole cover seat or structure opening.
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3.4 AVAILABILITY AND COST A. Availability: The Triplex Lining System is available in all major marketing areas in
the United States, Canada, Australia, Mexico and Western Europe.
B. Cost: The Triplex Liner System requires custom manufacturing and installation procedures tailored for each structure. The end result is a long-term solution to infiltration and H2S gas deterioration, with true value spread over the life of the liner.
3.5 WARRANTY
A. McNeil Technologies LLC and the Triplex Authorized Licensed Installer, jointly provides Twenty (20) Year unlimited and non-prorated Materials Warranty and Twenty (20) Year Labor Warranty for all Triplex Liners. Triplex fabrics and resins are warranted to be free of defects in materials and workmanship, to prevent infiltration, prohibit root intrusion and provide a surface coating resistant to sewer gases and chemicals typically found in domestic sewer collection systems. This warranty is for the repair or replacement of the liner as needed. B. McNeil Technologies LLC does not certify the structural integrity of existing structure or substructure, but the liner system will eliminate further deterioration due to sewer gases and significantly increase the life of the existing structure. In the case of industrial or chemical applications, warranty will be provided on a case-by-case basis.
3.6 MAINTENANCE
A. Although no maintenance is anticipated for decades, the Triplex Liner System is easily
repaired. Small holes or cracks can be repaired with EPOSeal™ Mastic. Larger
areas may be repaired using fiberglass material coated on both sides with EPOSeal™
Mastic for greater structural integrity. The liner may be core drilled through for the
addition of incoming lateral lines. EPOSEAL™ Mastic Grout is recommended for use
as a seal between the new line and the liner wall.
CMSD Project No. 324 Special Provisions – 7 of 11
ALTERNATIVE LINING SYSTEM
PART I GENERAL
1.1 PRODUCT DESCRIPTION
A. This work shall include the furnishing of all labor, materials, and equipment for
the rehabilitation of an existing manhole with a cured-in-place PVC
composite liner.
B. The manhole liner shall be manufactured to the shape of the manhole. The
fibrous portion of the liner shall be saturated with a modified epoxy resin,
then pressurized and cured in-place.
C. Fused seams will allow the liner to be inflated and pressurized between ½ - 8
pounds per square inch, with or without an inflation bladder.
D. The seams of the liner shall be sealed with fusion welding equipment. The
design shall be as described in US Patent 6,540,438 B2.
E. The exposed surface of the liner shall be white PVC.
1.2 LINER PERFORMANCE REQUIREMENTS
A. Liner shall be of the type that allows rehabilitation of a concentric, eccentric or
flat top manhole without removing the manhole ring and top section or corbel.
B. The liner shall be installed and cured in place via controlled curing by heat and
pressurization in the manhole to complete the curing process.
C. The lining of the manhole shall result in a structure to the shape and contour of the
existing manhole. The liner shall be installed and substantially bond to the
interior manhole substrate and be watertight, free of any joints or openings
other than pipe inlets, outlets and the cover frame opening.
D. Where indicated on the manhole schedule the lining shall be designed with
independent structural hoop strength for full height hydrostatic pressure as if the
liner were a secondary vessel inside the existing manhole. The manufacturer
shall design adequate liner thickness into the system with or without additional
fiberglass layers.
1.3 QUALITY ASSURANCE
A. Reference Standards: Comply with applicable provisions and recommendations
of the following:
1. ASTM D 695-10 Standard Test Method for Compressive Properties of
Rigid Plastics.
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1.4 SUBMITTALS
A. Copies of the manhole dimensions, installation instructions, and manufacturer’s
product data sheet to be submitted for the Engineer’s review.
B. If required, calculations for the round manhole lining that demonstrate hoop
strength under maximum hydrostatic conditions. The calculation shall assume
zero liner adhesion to the existing structure, but assume lateral support from
the existing wall. The calculated hoop stress shall be less than 11% of the
compressive strength as determined by appropriate ASTM test method.
PART 2-PRODUCTS
2.1 MATERIALS
A. Manhole interior walls and benches shall be patched with cementitious
patching/plugging compounds as manufactured by Pre-Blend Products, Inc., or
approved equal.
B. Channel reconstruction cement shall be Speed Plug as manufactured by
Euclid Chemical, formed cement concrete of 4,000-psi compression strength, or
approved equal.
C. As a minimum the manhole liner systems shall be composed of a multiple
layered composite. The primary layer shall be manufactured from 25 mils PVC
with 10 ounce per square yard polyester fleece. The surface hairs of the fleece
must be embedded in the molten PVC during the manufacturing process of the
material. Glued laminates are not allowed. Multiple Layers of fiberglass are
added to increase thickness and strength.
D. The fibrous body will be impregnated with a modified epoxy resin. Add
fiberglass and resin, for additional liner thickness.
AltLiner™ models:
CIPM™ 46 100 mills installed
CIPM™ 58 150 mills installed
CIPM™ 106 200 mills installed
CIPM™ XX Custom Design
E. Liner Thickness: The anticipated hydrostatic head “h” in feet above the bottom
of the invert and the Radius “R” in feet of the structure shall determine the
necessary liner thickness “t” in mils.
CMSD Project No. 324 Special Provisions – 9 of 11
2.2 APPLICABLE MANUFACTURERS
A. Products specified by named manufacturers are specified as a standard of
quality.
1. Alternative Lining Technologies, LLC. (the manufacturer of the
AltLiner™)
Phone: 800-747-4282.
2. Approved equal.
2.3 ACCEPTABLE LINER INSTALLERS.
B. Certified installer: Sancon Companies
5841Engineer Drive
Huntington Beach, CA 92649
Attn: Chuck Parsons
Phone: (714) 891-2323
B. Approved equal.
PART 3-EXECUTION
3.1 MAINTAINING WASTEWATER FLOWS
A. The OWNER shall be fully responsible for restricting the normal sewage flow
through the manhole where the specified rehabilitation work demands such
flow restriction. The CONTRACTOR will plan his work in order to
maintain flows and not interrupt sewer service. This may include night work. The
cost of any night work required will be included in the contract price of the
applicable item. The CONTRACTOR shall not perform work to manholes
until plans for bypass pumping or flow restriction have been submitted by the
OWNER and accepted by the CONTRACTOR. Additionally, no plugging of
existing Utility System Gravity Mains will be made without the approval of
the Utilities Department.
B. Unlined flow channel. Install a bridge or flow through tube and cut the liner
bottom near the flow line in the channel to expose the flow channel and give
access to the pipes. Plug the pipes entering the manhole through the wall and
trim the pipe opening to restore flow.
C. Lined flow channel. Plug the pipes entering the manhole and line the flow
channel to the edge of the pipe. Trim all pipe openings and restore the flow.
CMSD Project No. 324 Special Provisions – 10 of 11
3.2 PRE-INSPECTION
A. In general, the OWNER assumes responsibility for the structural integrity of
existing structure. Prior to beginning work, the manhole shall be visually
inspected and any areas of apparent structural damage shall be reported to the
OWNER for restoration.
3.3 CLEANING
A. All surfaces of the manhole shall be cleaned with a high-pressure water-jet
sprayer with an operating pressure of at least 5,000 psi. Pressure wash the
manhole to remove all dirt, grease, sand, and surface contaminants on the wall
and floor leaving a clean damp surface.
B. Badly deteriorated and pitted pre-cast manholes and brick manholes, with
missing bricks and grout, shall be mudded back to form a smooth compatible
surface for the liner.
3.4 PLUGGING RECONSTRUCTION
A. The stopping of active hydrostatic infiltration shall be accomplished by using
Speed plug as manufactured by Euclid Chemical or approved equal.
B. Water infiltration can also be stopped using expansion type grouts such as
Avanti or Seal Guard II.
3.5 CHANNEL RECONSTRUCTION
A. Remove all loose grout and rubble of existing channel. Rebuild channel if
required by shaping and repairing slope of shelves or benches. Work shall
include alignment of inflow and out flow ports in such manner to prevent the
deposition of solids at the transition point. All inverts shall follow the grades of
the pipe entering the manhole. Changes in direction of the sewer and entering
branch or branches shall have a true curve of as large a radius as the size of the
manhole will permit. Channels shall be shaped to allow entrance of
maintenance equipment into pipes including buckets, TV camera, etc.
B. Inverts shall only be lined where indicated on the plans “lined inverts”.
3.6 LINER INSTALLATION
A. Installation shall be by an installer that is qualified by the liner manufacturer.
The CONTRACTOR shall include the furnishing of all materials, equipment,
tools, and labor as required for the rehabilitation of the manholes selected,
including the installation of the interior liner.
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B. The installation of the approved liner system shall be in strict accordance with
the manufacturer’s instructions. This shall include the preparation,
installation, inflation, curing, and finishing operations, required for the
completion of the manhole rehabilitation process.
C. All safety rules and regulations, applicable laws and insurance
requirements shall be observed in storing, handling, use and application of the
liner materials, resins and any solvents.
D. Ventilation shall be provided to the workers at all times.
PART 4-WARRANTY, MEASUREMENT AND PAYMENT
A. The MANUFACTURER shall warrant to the OWNER in writing the
performance of the liner for a period of twenty years.
B. Payment for the rehabilitation of the structure shall be made at the contract
vertical foot price and shall include all necessary labor, material and equipment
to clean, seal off any water infiltration, prepare the walls, provide and install the
liner completely. The vertical foot measurement is defined as the distance
between bottom of invert and top of cover. Payment value is the product of
vertical foot price and vertical foot measurement.
END OF SECTION