CIPP Specifications for Client Use
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Sanitary Sewer Rehabilitation Using Cured-in-Place Pipe (CIPP)
PART 1 – GENERAL
1.1 SCOPE
A. It is the intent of this specification to provide for the reconstruction of pipelines and conduits by the installation of a cured-in-place pipe (CIPP) consisting of a thermosetting resin-impregnated flexible felt tube coated on one side with an impermeable plastic which is inverted into the original conduit by the use of a hydrostatic head or pressurized air. Curing is accomplished by circulating hot water or controlled steam throughout the length of the inverted tube to cure the resin into a hard, impermeable pipe with the plastic coating on the internal surface of the CIPP. The final product shall extend the entire length of the original pipe segment providing a continuous, tight-fitting and joint-less CIPP.
1.2 RELATED DOCUMENTS
A. Drawings and general provisions of the specifications and Contract.
B. This specification references ASTM F1216 (Standard Practice for Rehabilitation of Existing Pipelines and Conduits by the Inversion and Curing of a Resin-Impregnated Tube), ASTM D5813 (Cured-in-Place Thermosetting Resin Sewer Pipe) and ASTM D790 (Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics) which are made a part hereof by such reference and shall be the latest edition and revision thereof. Where conflicts exist between the referenced standard and this specification, this specification will govern.
1.3 PRODUCT AND CONTRACTOR QUALIFICATION REQUIREMENTS
The provided product shall have a 50 year design life, and in order to minimize the Owner’s risk, only proven products with substantial long term track records will be approved. All Contractors must submit proof that they meet the below product and installer requirements of this section with their bid.
In order for products and contractors to be deemed commercially acceptable and approved for this project they must meet the following criteria:
1. For a Manufacturer’s inversion liner Product 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.
2. The Manufacturer of the inversion liner Product must operate under a quality management system that is third party certified to ISO 9001:2000 or other internationally recognized organization standards. Proof of certification shall be submitted with the Bidder’s bid and required for approval.
3. Third Party Test Results for the sewer rehabilitation product resin system supporting the long-term performance and structural strength of the product shall be submitted for approval, and such data shall be satisfactory to the Owner. No product will be approved without independent third party testing verification.
4. For a Contractor to be approved by the Owner, the Contractor must satisfy all insurance, financial, and bonding requirements of the Owner, and must have successfully installed at least 500,000 linear feet of CIPP in wastewater collection systems in the United States.
5. For a Contractor to be approved by the Owner, the Contractor must submit with their bid correspondence from the Manufacturer stating that the Contractor is certified to install the Manufacturer’s inversion liner Product.
6. Contractor’s Qualifying Superintendent(s): the Contractor’s Superintendent(s) designated for this project must have had at least 5 (five) years of continuous active experience in the commercial installation of CIPP. This shall be documented to the Owner’s satisfaction in the form of a resume of work experience detailing scope of work (linear footage and CIPP diameters), location of work, and reference contact information for each project listed.
1.4 SUBMITTALS
A. The Contractor shall submit to the Owner or Owner’s Engineer documentation which may include shop drawings, ASTM Standards, and manufacturer’s data for the following items:
1. Lining materials to be installed.
2. Thermosetting resin to be utilized in producing the CIPP in accordance with these specifications.
3. Bypass plan layout.
4. Safety plan.
5. Design calculations for CIPP thickness of the liner system.
6. Procedures for preparing CIPP samples and testing of physical properties.
7. Pre-installation Inspection Reports. The submittal items listed above shall be submitted by Contractor to the Owner or Owner’s Engineer after Notice of Award and prior to beginning the work.
1.5 SAFETY
The Contractor shall carry out their operations in strict accordance with OSHA and the manufacturer’s safety requirements. Particular attention is drawn to those safety requirements involving working with scaffolding and entering confined spaces.
PART 2 – MATERIALS
2.1 LINER TUBE
A. The tube shall consist of one or more layers of absorbent non-woven felt fabric and meet the requirements of ASTM F1216, Section 5. The tube shall be constructed to withstand installation pressures, have sufficient strength to bridge missing pipe, and stretch to fit irregular shaped pipe sections.
B. The wet-out tube shall have a uniform thickness that when compressed at installation pressures will meet or exceed the calculated minimum design CIPP wall thickness.
C. The tube shall be manufactured to a size that when installed will tightly fit the internal circumference and length of the original pipe. In the event that under-sized pipe is present, the liner tube shall be manufactured so that overlap folds or wrinkles do not occur. Allowances shall be made for circumferential stretching during inversion.
D. The outside layer of the tube (before wet-out) shall be coated with an impermeable polyurethane or polyethylene plastic coating. This coating shall be an impermeable, flexible membrane that will contain the resin and facilitate monitoring of resin saturation during the resin impregnation (wet-out) process. This coating shall form the inner layer of the finished pipe and is required for enhancement of corrosion resistance, flow, and abrasion properties.
E. The tube shall be homogenous across the entire wall thickness containing no intermediate or encapsulated layers of any material. Additionally, no material shall be included in the tube that may cause delamination in the cured liner, and no dry or unsaturated layers shall be evident.
F. The wall color of the interior liner surface after installation shall be a light reflective color so that a clear detailed inspection with closed-circuit television equipment may be conducted.
G. The outside of the tube shall be marked for distance at regular intervals not to exceed 10 feet. Such markings shall include the Manufacturer’s name or identifying symbol. The tubes must be manufactured in the USA.
H. The minimum length shall be that deemed necessary by the Contractor to effectively span the distance between manhole sections of the segment to be lined unless otherwise specified. The Contractor is solely responsible for field verification of all pipe diameters and lengths prior to fabrication, wet-out and installation.
2.2 RESIN
A. The resin system shall be a corrosion resistant polyester or vinyl ester catalyst system that when properly cured with the tube composite meets the requirements of ASTM F1216, 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 which will comply with the structural and chemical resistance requirements of this specification.
B. The resin shall be shipped directly from the resin manufacturer’s facility to the CIPP wet-out facility. The resin shall not be sent to any intermediate mixing facility.
C. When requested by the Owner, the Contractor shall submit a Certificate of Authenticity from the resin manufacturer for each shipment to the wet-out facility to include the date of manufacture.
PART 3 – CIPP PRODUCT
3.1 STRUCTURAL REQUIREMENTS
A. The CIPP shall be designed as per ASTM F1216, Appendix X1. The CIPP design shall assume no bonding to the original pipe wall.
B. Long-term testing must have been performed for flexural creep of the CIPP pipe material to be installed. Such testing results are to be used to determine the long-term, time dependent flexural modulus to be utilized in the product design. This is a performance test of the materials (Tube and Resin) and general workmanship of the installation and curing as defined within the relevant ASTM standard. A percentage of the instantaneous flexural modulus value (as measured by ASTM D790 testing) will be used in design calculations for external buckling. The percentage, or the long-term creep retention value utilized, will be verified by this testing. Retention values exceeding 50% of the short-term test results shall not be applied unless substantiated by qualified third party test data to the Owner’s satisfaction. The materials utilized for the contracted project shall be of a quality equal to or better than the materials used in the long-term test with respect to the initial flexural modulus used in the CIPP design.
C. The Enhancement Factor ‘K’ to be used in ‘Partially Deteriorated’ Design conditions shall be assigned a value of 7.
D. 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 separation of the layers occurs during field sample testing, new samples will be required to be obtained from the installed pipe. Any reoccurrence may cause rejection of the work.
E. The cured pipe material (CIPP) shall conform to the structural properties, as listed below.
MINIMUM CIPP PHYSICAL PROPERTIES
| Property |
Test Method |
Cured Composite per ASTM F1216 |
Cured Composite Enhanced Resin |
| Modulus of Elasticity |
ASTM D790 |
250,000 psi |
400,000 psi |
| Flexural Stress |
ASTM D790 |
4,500 psi |
4,500 psi |
F. The required structural CIPP wall thickness shall be based as a minimum, on the physical properties in Section 3.1.E above or greater values if substantiated by independent lab testing and in accordance with the design equations in the Appendix X1. Design Considerations of ASTM F1216, and the following design parameters:
| Design Safety Factor (typically used value) |
= |
2.0 |
Retention Factor for Long-Term Flexural Modulus to be used in Design
(As determined by long-term tests described in Section 3.1.B and approved by the Owner) |
= |
50% - 75% |
| Ovality* (calculated from (X1.1 of ASTM F1216) |
= |
% |
| Enhancement Factor, K |
= |
See Section 3.1.C |
| Groundwater Depth (above invert of pipe) |
= |
ft. |
| Soil Depth (above crown of pipe) |
= |
ft. |
| Soil Modulus (only required for fully deteriorated design conditions) |
= |
psi |
| Soil Density (only required for fully deteriorated design conditions) |
= |
pcf |
| Live Load (only required for fully deteriorated design conditions) |
= |
H20 Highway |
| Design Condition (partially or fully deteriorated)* |
= |
* |
*Based on review of video logs, design conditions of pipeline can be fully or partially deteriorated. (See ASTM F1216 Appendix) The Owner will be sole judge as to pipe conditions and parameters utilized in design.
G. Any layers of the tube that are not saturated with resin prior to insertion into the existing pipe shall not be included in the structural CIPP wall thickness computation.
3.2 TESTING REQUIREMENTS
A. Chemical Resistance - The CIPP shall meet the chemical resistance requirements of ASTM F1216, Appendix X2. CIPP samples for testing shall be of tube and resin system similar to that proposed for actual construction. It is required that CIPP samples with and without plastic coating meet these chemical-testing requirements.
B. Hydraulic Capacity - Overall, the hydraulic cross-section shall be maintained as large as possible. The CIPP shall have a minimum of the full flow capacity of the original pipe before rehabilitation. Calculated capacities may be derived using a commonly accepted roughness coefficient for the existing pipe material taking into consideration its age and condition.
C. CIPP Field Samples - When requested by the Owner, the Contractor shall submit test results from field installations of the same resin system and tube materials as proposed for the actual installation. These test results must verify that the CIPP physical properties specified in Section 3.1.E have been achieved in previous field applications. Samples for this project shall be made and tested as described in Section 4.4.A.
PART 4 – EXECUTION
4.1 INSTALLATION RESPONSIBILITIES FOR INCIDENTAL ITEMS
A. It shall be the responsibility of the Owner to locate and designate all manhole access points open and accessible for the work, and provide rights-of-access to these locations. If a street must be closed to traffic because of the orientation of the sewer, the Owner shall institute the actions necessary to provide access during this for the mutually agreed time period. The Owner shall also provide free access to water hydrants for cleaning, installation and other process related work items requiring water.
B. Cleaning of Sewer Lines - The Contractor, when required, shall remove all internal debris out of the sewer line that will interfere with the installation of CIPP. The Owner shall also provide a dumpsite for all debris removed from the sewers during the cleaning operation. Unless stated otherwise, it is assumed this site will be at or near the sewage treatment facility to which the debris would have arrived in absence of the cleaning operation. Any hazardous waste material encountered during this project will be considered as a changed condition.
C. Bypassing Sewage - The Contractor, when required, 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 make the bypass. The pump(s) and bypass line(s) shall be of adequate capacity to accommodate the sewage flow. The Owner may require a detail of the bypass plan to be submitted.
D. Inspection of Pipelines - Inspection of pipelines shall be performed by experienced 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 shall be noted and corrected. A DVD and suitable written log for each line section shall be produced for later reference by the Owner.
E. Line Obstructions - It shall be the responsibility of the Contractor to clear the line of obstructions such as solids and roots that will prevent the insertion of CIPP. If pre-installation inspection reveals an obstruction such as a protruding service connection, dropped joint, or a collapse that will prevent the installation process, that was not evident on the pre-bid video and it cannot be removed by conventional sewer cleaning equipment, then the Contractor shall make a point repair excavation to uncover and remove or repair the obstruction. Such excavation shall be approved in writing by the Owner's representative prior to the commencement of the work and shall be considered as a separate pay item.
F. Public Notification - The 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 8 hours. A public notification program shall be implemented, and shall as a minimum, require the 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. The Contractor shall also provide the following:
1. Written notice to be delivered to each home or business the day 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 problems.
2. Personal contact with any home or business, which cannot be reconnected within the time stated in the written notice.
G. The Contractor shall be responsible for confirming the locations of all branch service lateral connections before beginning the installation of the CIPP.
4.1 INSTALLATION
A. CIPP installation shall be in accordance with ASTM F1216, Section 7, with the following modifications:
1. Resin Impregnation - The quantity of resin used for tube impregnation shall be sufficient to fill the volume of air voids in the tube with additional allowances for polymerization shrinkage and the potential loss of resin during installation through cracks and irregularities in the original pipe wall, as applicable.
2. Tube insertion - The wet out tube shall be inverted into the pipeline using as defined within relevant ASTM standards previously stipulated. The tube should be inverted through an existing manhole or approved access point and fully extend to the next designated manhole or termination point.
3. Temperature gauges shall be placed between the tube and the host pipe’s invert position to monitor the temperatures during the cure cycle.
4. Curing shall be accomplished by utilizing hot water under hydrostatic pressure or steam pressure in accordance with the manufacturer’s recommended cure schedule. A cool-down process shall be conducted that complies with the resin manufacturer’s specification.
4.2 REINSTATEMENT OF BRANCH CONNECTIONS
A. It is the intent of these specifications that branch connections to buildings 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.
4.4 INSPECTION
A. CIPP samples shall be prepared for each installation designated by the owner/engineer or approximately 20% of the project’s installations. Pipe physical properties will be tested in accordance with ASTM F1216, Section 8, using either method proposed. The flexural properties must meet or exceed the values listed in the table on page 5 of this specification, Table 1 of ASTM F1216 or the values submitted to the Owner/engineer by the contractor for this project’s CIPP wall design, whichever is greater.
B. Wall thickness of samples shall be determined in a manner consistent with 8.1.2 of ASTM D5813. The minimum wall thickness at any point shall not be less than 87.5% of the specified design thickness calculated in 3.1.F of this document.
C. CIPP installation may be inspected visually if appropriate, or by closed-circuit television. Variations from true line and grade may be inherent because of the conditions of the original piping. No infiltration of groundwater should be observed. All service entrances should be accounted for and be unobstructed.
4.5 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.
4.6 PAYMENT
Payment for the work included in this section will be in accordance with the prices set forth in the proposal for the quantity of work performed. Progress payments will be made monthly based on the work performed during that period
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