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HomeMy WebLinkAboutSliplining WRIGHT-PIERCE .1 LETTER OF TRANSMITTAL Engineering a Better Environment 169 Main Street, 700 Plaza Middlesex,Middletown, Connecticut USA 06457 Tel: 860-343-8297 Fax: 860-343-9504 DATE: 0812012012 JOB NO 12438C ATTENTION: Mr.Rick Hill TO: RE: Gerber Construction Company Phase I Sewer System Improvements— I Nutmeg Drive Town of South Windsor, CT Ellington, CT 06029 WE ARE SENDING YOU 0 Attached E-1 Under separate cover via the following items: Shop drawings Prints Plans Samples Specifications Copy of letter Change order W-P COPIES DATE SHOP# SPEC# DESCRIPTION 1 08120112 13 02656 Sli lining THESE ARE TRANSMITTED as checked below: For approval Approved as submitted Resubmit copies for approval For your use Approved as noted Submit copies for distribution As requested Returned for corrections Return corrected prints For review and comment FOR BIDS DUE 19 PRINTS RETURNED AFTER LOAN TO US REMARKS: COPY TO: C.Fred Shaw-Superintendent -Bureau of SIGNED: t Pollution Control File(2) Dennis A.Dievert-Wright-Pierce If enclosures are not as noted,kindly notify us at once. WRIGHT-PIERCE 1 Engineering a Better Environmen.Mt SUBMITTAL REVIEW FORM PROJECT: South Windsor Phase I Sewer Improvements PROJECT NO.: 12438C CONTRACT NO.: ENG/TA: LMM/BLS DATE RECEIVED: 8/16/12 CONTRACTOR: Gerber Construction Company TRANSMITTAL NUMBER: Via 8/16/12 Email SHOP DRAWING NUMBER: 013 SPECIFICATION SECTION OR DRAWING NO.: 02656 DESCRIPTION: Sliplining NO EXCEPTIONS TAKEN ( ) MAKE CORRECTIONS INDICATED - SEE REMARKS ( X ) CONDITIONAL-SEE REMARKS ( ) REVISE AND RESUBMIT- SEE REMARKS ( ) REJECTED - SEE REMARKS ( ) Review is only for conformance with the design concept of the Project and compliance with the information given in the Contract Documents. Contractor is responsible for dimensions to be confirmed and correlated at the job site; for information that pertains solely to the fabrication processes or to techniques of construction; and for coordination of the work of all trades. REMARKS: The submitted materials are approved for use on the project with the following comments: 1. Verify that the manufacturer's field service department shall be available via telephone during normal business hours to address any issues as it relates to installation of the pipe material. The manufacturer shall also be prepared to provide field service personnel to assist and provide advice on issues during the installation of the pipe in the field. These services shall be provided at no additional cost to the project. 2. General Contractor to submit on grout to be used to fill annular space. 3. General Contract to submit a written plan on how this pipe shall be conducted in accordance with Section 02656, Item 1.3.13.2 and Item 3.2 to supplement the information provided by the manufacturer. 4. General Contract to submit CCTV tapes in accordance with Section 02656, Item 1.3.C. By: Dennis Dievert Jr. Date: August 16,2012 Wright-Pierce Page 1 of 1 HOBAS PIPE USA 1413 Richey Road Houston,Texas 77073 Tel.: 281/821/2200 M Fax:281/821[7715 HOBAS info@hobaspipe.com www.hobaspipe.com IMPORTANT INFORMATION CONCERNING SUBMITTALS We have been requested to furnish these Submittals for your project. The information furnished is necessary in order that Hobas Pipe USA, Inc. produce the correct pipe and/or fittings required and ship them in the appropriate timeframe to complete your project. In order to accomplish this, these submittals must be returned to Hobas Pipe USA, Inc. as quickly as possible. The submittal must be "approved", "approved as noted", "returned for revision", "rejected", etc. If fittings are involved, information may be required of the contractor or engineer as to angle verification, stubout location, etc. Please understand that if we do not receive final approval of the submittals we can not manufacture the material on your order, and your project will be impacted. ONLY WRITTEN APPROVAL IS ACCEPTABLE...VERBAL APPROVAL WILL NOT BE TAKEN VIA TELEPHONE OR FROM SALES PERSONNEL. Thank you for your understanding. We will strive to make this project as trouble free as possible for all involved. Hobas Pipe USA, Inc. Rob Epstein Commercial Manager r 1 HOBAS PIPE USA Pipe Submittal for: Phase I Sewer System Improvements submitted to: Town of South Windsor, CT c/o Gerber Construction, Inc. Ellington, CT submitted by: HOBAS PIPE USA 1413 Richey Road Houston, TX 77073 on: August 1, 2012 I HOBAS PIPE USA 1413 E_ Richey Road Houston,Texas 77073 August 1,2012 Tel.:281/82112200 Fax: 281/821/7715 HOBAS info®hobaspipe.cwm Mr. Ron Gerber wwwhobaspipe.com Gerber Construction, Inc. 1 Nutmeg Drive Ellington,CT 06029-3899 860-875-6684 Subject: Phase I Sewer System Improvements Pipe Submittal Dear Ron: The following and the attached constitute our pipe submittal for the above referenced project: 1. Product Data: Application: Sanitary Sewer Installation: Sliplining Product Description: Centrifugally Cast, Glass-Fiber-Reinforced Thermosetting Polyester Mortar Pipe Cell Class: Type 1, Liner 2, Grade 3 per ASTM D3262 Diameter: 27"(Nominal) Stiffness: 145 psi (min) Grout Pressure 29 psi(max) Joint Type: Flush Bell/Spigot Push Capacity: 46 ton (Straight Alignment, FS=3.0) Section Length: 1 Oft. Nominal(+/-2", 90%Typical) 2."Certification of Compliance"with ASTM D3262, per attachment 1. 3.Joint&Fitting Details, per attachment 2. 4.Standard Transportation, Storage, Handling, Installation, Assembly, &Cutting Instructions, per attachment 3. 5. Pipe Performance Calculations, per attachment 4. 6.Test Reports, per attachment 5. Please feel free to contact me if additional information is required. Sincerely, Arturo R. Guerrero Engineering Associate HOBAS PIPE USA 1-800-856-7473 aguerreroAhobaspipe.co m cc: RCT, RRG,JDA,JMele a Attachment # 1 of: HOBAS Pipe Submittal fo r: Phase I Sewer System Improvements it HOBAS PIPE USA 1413 E. Richey Road Houston,Texas 77073 August 1, 2012 Tel.:281/82112200 Fax: 281/821/7715 HOBAS into®hobaspipe.com www.hobaspipe.com Certification of "COMPLIANCE WITH SPECIFICATIONS" HOBAS Pipe USA certifies that the pipes to be manufactured for use on the Phase I _ Sewer System Improvements Project, will be in accordance with ASTM D3262, Type 1, Liner 2, Grade 3 (Standard Specification for Fiberglass Sewer Pipe), which includes compliance with ASTM D3681 (Standard Test Method for Chemical Resistance of Fiberglass Pipe in a Deflected Condition) and ASTM D4161 (Specification for Fiberglass Pipe Joints Using Flexible Elastomeric Seals). Signed, Arturo R. Guerrero Engineering Associate HOBAS PIPE USA Attachment# 2 of: HOBAS Pipe Submittal for: Phase I Sewer System Improvements a Flush Bell-Spigot Several joint designs are avail- Joint • able to meet the requirements of many different applications. Service The FWC coupling is normally uti- Non-Pressure Pressure Installation lized for direct bury,aboveground, Direct Bur FWC Coupling FWC Coupling and some other installations.For y p g p g sliplining,jacking, and tunnelgz 51ip1lning . Low Qrofile Pressure installations, special joints are Bell Spigots ReUriing available. Closure couplings are available for tie-ins.Joint dimen- Jacking Flush Flush sions are given in AppendixC. Bell-Spigot FWC Coupling --Ali' nd FWC Coupling FINC Coupling _3r Tunnel Carrier Pipe Flush Pressure Relining Joining • •r HOBAS HOB Bell-Spigot * Couplings Tie ms Closure Coupling Steel Mechanical Coupling "(Approximate average ' ' *May use flush bell-spigot joint in very tight fit situations. alignment) •• • '"`May use FWC coupling in some situations. Nominal FWC Flush PipeSize and LPB Minimum Radius of Curvatur- for VariousDeflected J 1500 750 ..f Max Max Offset(inches) Min Radius of Curvature(feet) 20 1700 850 Deflected _ _ Angle in 2 2000 1000 Degrees' 27 --miq-S T 1075 30 2500 1250 3 3 6 12 95 191 382 ­,33 2700f" i 350_ _: 2 u_:2. t 4 8, i:43... 28b. 573 36 3000 1500 1.75 1.75 3.5 7 164 327 917 3400 170_ . 1.5 _15 ., 3 _.... 6 191 _ 382.> 42 3500 1750 1.25 1.25 2.5 5 229 458 655 44 286 573 1G 45 3750 1875 0.75 0.75 1.5 3 383 764 1528 Y48,4: 4000n" _JUDO_ OS 05_ A n 1. 2 r = 573 71 '2292 51 4250 2125 *For other angle possibilties,calculate the radius of curvature by the equation: Z250 Radius of Curvature=R=(U2)/tan(8/2).Where 8=deflection angle in degrees.L=section length(ft). 57 4750 2375 Max Offset=(L)tan8.L=section length(in). 63 5250 2625 �5 �2750, ' 69 5750 2875upling= - = 78 6500 3250 �t 85 7000 3500 O 7500 Note:Always join pipes in"straight"align- 96 8000 4000 oeflecfion Angie ment and then offset to the desired Radius of{ rvature r angle afterwards. 1 , 110 9500 4750 F_: . } Flush Bell-Spigot s Description &Capability The flush bell-spigot joint con- sists of an integral straight bell fixed to one pipe end that seals to the spigot end of another pipe by compressing an elas- tomeric gasket contained in a groove on the spigot.The joint has approximately the same O.D. as the pipe,so when assembled, the joint is essentially flush with the pipe outside surface.It is de- signed for nonpressure service in jacking and tunnel carrier instal- lations,although it may be used in nonpressure relining applications. Typical allowable joint angular ' £ deflection is between 1 and 2 degrees depending on the spacer thickness and joint configuration. t Joining force is substantially less than the FWC coupling joint. Jacking pipes have rubber-ring-sealed flush bell-spigot joints for quick assembly. Flush bell-spigot. JointFlush . • Nominal Diameter(inches) Gap(inches) 30-42 0.70 66-110 2.00 *The corresponding angle for each allowable joint gap maybe calculated by using the formula:deflection angle in degrees=8=arctan(gap in Inches/QD.in inches). *This joint gap is provided for sealing purposes only and does not address installation loads.See Section 14 for installation specific information. r FLUSH RELINING JOINT DETAIL H B G 1 J D I F E A A B C D E F G J Nominal PIPE O.D. Min Spigot Max Bell Nominal I.D. Min Bell I.D. Max O.D. Min Bell Max Gap(in.) Diameter (In.) Length(in.) Length(in.) (in.) (in.) Spigot(in.) Thickness(in.) 2r 0 1 28.0 3.2 1 3.1 26.3 27,54 27.52 0.23 0.60 Max Joint Angle: 1.25" L 20 ft 10 ft 5ft H = Cosmetic Putty Filler Min Radius of Curvature: R(ft) 916 458 229 I = Gasket Groove; gasket not shown for clarity • DATE AMJ BY REV H 0 BAS 11/9/07 MJ t t Small Relining Gasket - Finned 0,551'±0,015' I 35'±2° R0,013' 0,394'±0,010' 0,197' 0,024" 0,026" R0,042' 0.066' - R0,184' R0,034' 0,026=- 0,144'±0,010" 0,068' Ft 0,068' 0,157'±0,010'--I 0,160'--_� 0,157"±0,010' 0,787'±0,020" 0,144'±0,010' HeDATE DRWN. BY REV *For Pipe Sizes 18"0 Through 28"0 HOBAS 6/27/2008 AMJ Appendix Dimensions ; Weights Nominal Nominal Outside Diameter,OD(in.} Pipe FWC Cou lin Low Flush Size PN 0 Profile Bell- Cn•? PN 50 PN 100 PN 150 PN 200 PN 250 Bell Spigot 18 21.3 21.3 21.3 21.3 21.4 20.4 19.5 20 23.4 23.4 23.4 23.4 23.6 22.5 21.6 24 27.6 27.6 27.6 1 27.7 27.9 26.8 25.8 27 28.0 28 31.9 31.9 32.0 32.1 32.3 31.0 30.0 30 33.9 33.9 34.0 34.2 34.4 33.0 32.0 33 35.9 35.9 36.1 36.3 35.0 34.0 36 40.2 40.2 40.4 40.6 39.3 38.3 41 44.9 44.9 45.2 45.5 44.0 42.9 42 46.5 46.5 46.8 47.2 45.6 44.5 44 47.9 47.9 48.2 48.6 47.0 45.9 45 49.7 49.7 50.0 50.4 48.8 47.7 48 52.8 52.9 53.2 53.6 51.9 50.8 51 56.0 56.1 56.5 56.8 55.0 53.9 54 59.2 59.4 59.8 60.1 58.2 57.1 57 62.2 62.5 62.8 61.2 60.0 60 65.2 65.5 65.9 1 64.1 62.9 63 68.3 68.7 69.1 1 67.2 66.0 66 71.6 72.0 72.4 1 70.4 69.2 69 74.9 75.4 75.8 73.8 72.5 72 77.9 78.3 78.8 76.7 75.4 78 84.2 84.7 85.3 82.9 81.6 84 89.6 90.2 88.4 87.0 85 91.4 92.0 90.0 88.6 90 97.1 97.8 95.7 94.3 96 102.5 103.1 101.0 99.5 104 111.1 111.7 1109.5 108.0 110 117.2 117.5 1 115.5 114.0 O.D. FLUSH BELL-SPIGOT November 03,2004 EPDM&Nitrile Compound Properties Hardness, Shore A 55—60 Tensile Strength,min(PSI) 1500 300%Tensile MOE, min. (PSI) 900 Typ. Ult.Tensile Elongation, min(%) 400 Compressions Set—22 hr. (%), 25%orig. defl. * 700C 20 % Oven Aging(158 ° F, 96 hr.) *Hardness, Shore A +8 Max *Tensile Strength -15 %Max *Ult. Tensile Elongation -20%Max Low Temperature Resistance (7 Days,-10° C) *Hardness, Shore A +15 Max *Brittle Point -55 OF Ozone Resistance(72 hrs., 40°C, 50 ppm) No Cracks Water Absorption(48 hrs., 70°C) Max. 5 %V Tear Strength, Die B (lb. /in.) Min. 200 4 l Attachment# 3 of: HOBAS Pipe Submittal for: Phase I Sewer System improvements HOBAS HOBAS PIPE USA Technical Advice Sheet Handling, Unloading, Storage, and Inspection General: Care must be taken when unloading and handling HOBAS Pipes. Severe impact with the ground, forklift tips, or other objects can cause damage to the pipe. Safety: Use extreme caution while handling pipes to avoid dropping or rolling on an unsuspecting person. Equipment and Materials: Forklift Cherry Picker Crane Nylon Strap Front End Loader Chock Note. Do not use chains or wire cables to handle or move HOBAS Pipes If in doubt, seek advice from: HOBAS PIPE USA 800-856-7473 } l Handling Storage 1. Severe impact with the ground or Short Term- other objects can damage the pipe. If possible,lay pipe on flat level ground. 2. Never use chains or wire cables to Avoid setting pipe on rocks or other handle HOBAS pipes. Use a fabric objects which would cause a point load. strap or carefully use a forklift. Long Term- 3. Avoid letting the weight of the pipe 1. For long term storage, it is best to rest on the coupling or bell end. store HOBAS pipe in the same 4. Avoid setting pipes on rocks or very arrangement as it arrived on the uneven ground. A point load with a truck. To avoid damage or deforma- hard object can damage the pipe. tion to the bell ends,do not allow the 5. Be aware of the location of pipe ends couplings/sleeves to rest against while moving. An end or coupling each other can be easily damaged by an impact. c0UPUNG1SLEEVE—___, Unloading PIPE 1. After the shipping straps have been 64 removed, use a cherry picker or PIPE crane with a nylon strap or a fork lift to remove the top pipes one at a TIMBER time. 2. Always use timbers and chocks 2. Take care that fork tips do not strike between layers when stacking pipe. other pipes. 3. It is advisable to re-inspect pipe after 3. Pipe sections can be lifted with one long term storage to assure no dam- support point(using a strap), age has occurred during storage or although two support points may handling. If storing pipe for a pro- increase control. longed period of time(over six 4. A leaning or off-center load is months)contact HOBAS for further extremely dangerous. When unload- considerations. ing,tie the ends of the pipe dunnage 4. Use the following chart to determine to the trailer to prevent them from recommended stacking height of flipping over. Remove the uphill pipe your pipe. first. Be careful that the second pipe does not roll. Diameter #of pipes in stack REME THIS EFIRST 1 8-20 4 PIPE PIPE CHOCK 24-30 3 36-60 2 DUNNAGE PIPE PIPE —CHAIN >60 1 •� Along ©itchGne- 1. String the pipe as near as possible to 5. It is up to the installer to determine the ditch to avoid excess handling. the best and safest method to unload 2. String the pipe on the opposite side special pieces(fittings, manholes, of the ditch from the excavated etc.). Use special caution to avoid material. damaging joint ends. Avoid picking 3. Place pipe so that it will be protected up the special pieces by branches. from traffic and equipment during the Use the main pipe. construction process. If in doubt, seek advice from: HOBAS PIPE USA 800-856-7473 Inspection Procedures 1. Make an overall inspection of the 6. Check the factory markings on the loaded truck. If the load is intact, pipe to assure that you have the ordinary inspection while unloading correct pipe. The pipes are marked should be sufficient to see if the as follows: pipe has arrived undamaged. 2. If the load has shifted during transit, DIA XX PN XXX SN XX each pipe needs to be carefully CODE XXXXXX)00( inspected for damage. Internal inspection is necessary for any Where: pipes that have exterior scrapes, DIA= nominal diameter(in) gouges, or impact marks. PN = pressure rating (psi) 3. Check total quantities against the (PN is left off gravity pipes) bill of lading. SN =stiffness class (psi) 4. Any damaged or missing items CODE= production code should be noted on the bill of lad- ing. Have the carrier's representa- 7. If damage is found on a pipe, con- tive sign your copy of the receipt. tact a HOBAS Field Technician to Make a prompt claim according to discuss the possibility of a repair. the carrier's instructions. 5. Do not dispose of any damaged material. The carrier will notify you of the procedure to follow. If in doubt, seek advice from: HOBAS PIPE USA 800-856-7473 i i HOBAS" Long-Term Outdoor Storage Pipes, Joints&Fittings 1)) All resin rich surfaces(pipe interior, FWC coupling exterior, all laminations) exposed to the sun for extended time periods(typically 1 year plus)will perform and weather best, if protected from UV attack. 2)) For pipes,this is most easily accomplished by storing them in a north-south orientation with the bell (or coupling)at the south end.Then cover the entire end and the coupling (or bell)with black (opaque)poly sheet. 3)) Check pipes vertical and horizontal diameter, Over an extended storage period, the pipes will typically assume a"permanent"set(new memory)of--25% of any deformation. If this"deflection" is unacceptable, rotate the pipes 90 degrees every several months or— halfway through their anticipated storage time. FWC Couplings with Nitrile Gaskets 1)) Nitrile gaskets are sensitive to UV exposure.Any nitrile gaskets that will be exposed to sunlight for more than 30 days (1 month)should be protected from UV attack to avoid degradation. 2)) For loose nitrite gaskets this is easily accomplished by storing them indoors until usage. 3)) For FWC couplings, cover the gasket or the end of the coupling with black (opaque) poly sheet or other dense material to prevent sunlight exposure to the gasket. RCT 3-4-10 Rigid Connections Rigid connections of pipes (such as to structures, to manholes or at the ends of encasements) create additional installation challenges to achieve buried success. The new issues caused by connections such as these include shearing at the interface, beam bending of the pipe, over rotation of joints, excessive joint pullout(draw) and differing support conditions across joint locations. It is frequently a common practice to incorporate a joint(or two joints) immediately adjacent to the"rigid"connection to minimize the effects of potential differential settlement between the manhole or structure (or encasement) and the attached (connected) pipe(s). At first thought, this appears to be a sound engineering approach. While this practice does aid in safely accommodating differential settlements (shearing) and minimizing of pipe beam bending, it increases the risk of excessive joint angular deflection, unacceptable joint draw and differential pipe deflection across joints with different support conditions (i.e. pipe on one side rigidly supported (concrete encased— likely zero deflection)and pipe on the opposite side elastically supported (soil and backfill—likely 2% +/-deflection)). The last item (differential pipe deflection across a joint), when of sufficient magnitude (typically over 0.5"), can result in joint leakage and/ or damage. Therefore, in many instances (particularly larger diameters and deep covers), the installation may be most successful by locating the first joint away from the rigid connection by a distance of at least 2 or 3 pipe diameters. Doing this will likely create a very similar pipe support condition across all joints, which usually results in nearly equal pipe deflections on both sides of the joint,thereby maximizing the joint performance. This procedure will, however, create a cantilever configuration for the first pipe exiting the rigid connection and does little to aid potential differential settlements. Having a cantilevered pipe also increases the risk of excessive pipe beam bending and shear at the interface, however,these potential risks can be greatly minimized by adequate bedding beneath the pipe to provide proper longitudinal support. Regardless of joint proximity to rigid connections, a successful installation must achieve similar pipe deflections across joints and avoid significant differential settlements. Joints may be located anywhere when these items are well controlled. In our experience, it is generally easier to achieve good, uniform longitudinal support than to control buried deflections to very small amounts.Therefore,for larger diameters (>36"to 42"typically), we have found it's best to locate joints away from the rigid connection interface. For smaller diameters (<24"to 30"), one may be most successful having a joint(s) in close proximity to the rigid connection interface. S Sliplining (FR) Flush Relining Bell-Spigot Allowable Compressive Load B1 Existing Pipe Preparation P Norrm. Min.Pipe Nan. Mm Pipe Safe Q.D. Wall Pipe Thickness® Compressive Q{(L DW. fin.) Thickness. Stiffness Gasket L Pushing 101& The existing sewer may be main- G".) fin.) Groove "Straight' operation during the 4 (U.S.tons) tained in o p g 18 19.5 0.75 426 0.34 30 43 relining process. Obstructions 20 21.6 0.75 310 0.34 34 48 such as roots, large joint off- 24 25.8 036 187 0.35 42 62 sets,rocks or other debris,etc. 27 28.0 0.76 145 0.35 46 68 that would prevent passage or 28 30.0 0.76 117 0.35 49 73 damage the liner pipe sections 30 32.0 0.86 143 0.36 54 87 must be removed or repaired 33 34.0 0.87 123 0.37 59 94 P 36 38.3 0.90 95 0.40 73 110 prior to installing the new pipe. 41 42.9 0.96 83 0.44 91 131 Prior to starting the liner inser- 42 44.5 0.99 82 0.46 99 140 tion,verify the existing pipe di- 44 45.9 1.02 82 0.47 105 148 ameter is sufficient by pulling a 45 47.7 1.05 80 0.49 114 158 mandrel through the line. 48 50.8 1.09 74 0.51 127 175 51 53.9 1.13 69 0.53 141 192 54 57.1 1.17 65 0.55 155 210 It must be determined that the 57 60.0 1.21 62 0.58 173 225 rehabilitated pipeline will be suf- 60 1 62.9 1.27 62 0.61 191 251 ficient structurally to cant' the 63 1 66.0 1.33 62 0.64 211 276 overburden loads for the intend- 66 69.2 1.45 1 71 0.66 228 315 ed design life. 69 72.5 1.47 64 0.67 243 335 72 75.4 1.A9 59 0.68 257 352 78 81.6 1.53 51 0.71 292 393 84 87.0 1.57 45 0.75 330 430 B2 Liner Pipe Insertion 85 88.6 1 1.58 43 0.76 342 440 90 94.3 1.66 42 0.82 394 491 Liner pipes may be pushed or 96 99.5 1.75 42 0.88 448 547 pulled into the existing pipe.The 1 104 108.0 1.85 39 0.94 521 628 pipes must be inserted spigot 1 110 114.0 1.94 38 0.99 580 695 end first with the bell end trail- ing.Sometimes the leading pipe end inside of the bell as shown joints,see the table on page 48 spigot end is protected by a in Figure 17.DO NOT apply the for typical allowable push loads. nose piece designed to ride-up pushing load to the end of the Allowable safe jacking loads and over off-set joints and other bell. Assure that the safe (F of may be reduced by point load- minor inconsistencies or debris S=3)jacking loads given in the ing(i.e.pushing through cures). in the invert.The pushing force above table are not exceeded. Maximum allowable joint angu- must be applied to the pipe wall For pipes with flush bell-spigot lar deflection is given on p.25. NOBAS PIPE �, � EXISTING PIPE WALL x '� PUSHING OR PULLING RING EXIS77NG PIPE WALL Small access pits needed for sliplining with HOBAS pipes save time, money FIGURE 17-Pipe Insertion and surface disruption. 4 4 1 B3 Laterals Laterals may be typically recon- nected to the new liner pipe us- ing "Inserta Tees" or similar wj® accessories. B4 Grouting - Grout the annular space be- tween the OD of the installed liner pipe and the ID of the ex- isting pipe with a cement or chemical based grout. Mini- mum compressive strength of Lateral Service reconnection using an"tnserta Tee': the grout shall be as required to assure the structural ad- equacy of the rehabilitated pipe. During grout placement,assure that the safe(F of S=2)grout- ing pressure given in the table below is not exceeded and that the grout density, lift heights and sewage flow depth are co- ordinated to control the liner pipe flotation and deformation to within allowable limits. :. ' gNNI Fluid Safe Grouting Pressure(Ps) Max.- None overIZ "/nserta Tee"installed in HOBAS Pipe. Flow Dia. level or to Difference low full <_5% SN-4 SN=3 5 20% SN-6 SN-5 >20% SN-7 SN-6 Chart A { Notes: Dia Difference= 1I0 Host Pipe-OD Liner Pioel x 100% OD Liner Pipe SN is nominal pipe stiffness in psi P F.4 Underside(inside)of"lnserta Tee"installation. Standard Installation Requirements for Sliplining with Hobas USA Centrifugally Cast Fiberglass Pipes A. Pipe Handlinq 1. Pipes may be lifted at one support point (properly balanced). 2. Rigging in contact with the pipe should be fabric straps, ropes or other pliable materials. 3. Avoid the use of steel cables, chains or other materials that may damage the pipe surface. If used, sufficient care, padding or protection must be included to prevent gouging, cutting or otherwise damaging the pipe. 4. Under no circumstances may the pipe be lifted with hooks inserted through the pipe ends. B. Transportation When pipes must be transported the following precautions should be followed: 1. Flat bed trailers are best utilized. 2. Pipes shall be separated and supported on flat timbers with checks to prevent rolling and side-to-side or vertical contact between pipes. 3. Timber supports shall contact only the pipe wall (no joint surfaces). 4. Two support locations per pipe section are necessary. Ideally these are located l of the section length from each end. 5. No bells, couplings or any other joint surface shall be permitted to contact the trailer, supports or another pipe. 6. Anchor strips shall be as described for pipe handling and are best applied at support locations. 7. Stacking limits should be in accordance with DOT and other applicable regulations. C. Pipe Storage 1. Pipes are best stored on the shipping dunnage as described in "Pipe Transportation." 2. When stored directly on the ground, the section weight must not be supported by the bell, coupling or any other joint surfaces. 3. Also, the pipe should not be resting on any rocks, boulders or other hard debris that may cause a point load sufficient to gouge, crack, puncture or otherwise damage the pipe wall. D. Existing Pipe Preparation 1. The existing sewer may be maintained in operation during the relining process. 2. Obstructions such as roots, large joint off-sets, rocks or other debris, etc. that would prevent passage or damage the liner pipe sections must be removed or repaired prior to installing the new pipe. 3. It must be determined that the rehabilitated pipeline will be sufficient structurally to carry the overburden loads for the intended design life. E. Liner Pipe Insertion 1. Liner pipes shall be inserted one section at a time through an access pit constructed above the existing sewer. The top of the existing sewer should be removed down to springline level (half- way). 2. It is normally helpful to have a centering "nose" fixture on the lead pipe to help passage over small offsets, rough areas, etc. 3. Liner pipes may be pushed or pulled into existing pipe. The pipes must be inserted spigot end first with the bell end trailing. 4. The pushing force must be applied to the pipe wall end inside of the bell as shown in Figure 1. DO NOT apply the pushing load to the end of the bell. 5. Assure that the safe (F of S = 3)jacking loads given in Table 1 are not exceeded. DO NOT force pipes into the existing sewer. Note that safe push loads are lower when the flush bell-spigot joint is used. 2 M F. Pipe Assembly 1. Before each section is pushed or pulled completely out of the access pit, stop the insertion process and temporarily suitably wedge, brace or otherwise adequately restrain the previously inserted pipes against continued insertion. 2. Place the next section to be inserted into position and push or pull it's spigot end into the last trailing bell to compress the gasket and thereby "male-up" the connecting joint. Lubricate non-submerged portions of the bell interior and spigot interior. 3. Joints are most easily assembled in straight alignment. 4. Maximum joint angular deflection for the Low Profile Bell Joint is as noted below. This results in maximum off-sets and minimum curve radii as follows: Minimum Radius of Pipe Joint Maximum Offset(in.) Curvature (ft.) Diameter Angle Section Length (ft.) Section Length (ft.) (in.) (degrees) 5 10 20 5 10 20 12 to 30 2.0 2 4 8 143 286 573 33 to 42 1.5 1.5 3 6 191 382 764 48 to 110 1.0 1 2 4 286 573 1146 G. Grouting 1. Grout the annular space between the OD of the installed liner pipe and the ID of the existing pipe with a cement or chemical based grout. 2. Minimum 28-day compressive strength of the grout shall be as required to assure the structural adequacy of the rehabilitated pipe. 3. Assure that the lift heights, grout density and sewage flow depth are coordinated to control the liner pipe deformation to within allowable limits. Point loads causing excessive dents or bulges should be avoided. Maximum pipe diameter deflection is 5%. 4. During grout placement, assure that the safe (F of S approx. 2.0) grouting pressure is not exceeded. Failure to control this process within this limit may collapse the pipe. 3 w 5. Safe grouting pressure (psi) is determined by the diameter difference between the existing host pipe and the OD of the liner pipe, stiffness and the fluid flow level as listed in the following table: Maximum Safe Grouting Pressure, psi Dia / Fluid None or Low Over% to Full Difference / Level <_ 5% SN /4 SN /3 <_ 10% SN /5 SN /4 <_ 20% SN /6 SN /5 > 20% SN /7 SN /6 SN is nominal stiffness in psi Dia Diff:= ID Host Pipe— OD Liner Pipe OD Liner Pipe 4 z HOBAS HOBAS PIPE USA Technical Advice Sheet Cutting HOBAS PIPE General: HOBAS centrifugally cast fiberglass pipes have a smooth and uniform exterior surface. This allows the pipe to be cut anywhere along its length and joined using the FWC or closure coupling. Chamfering of the pipe ends is the only preparation needed Safety: Cutting of HOBAS fiberglass pipes creates silica sand and fiberglass dust. if is advisable to wear a dust mask or respirator, eye protection, and gloves when cutting or grinding, as a minimum. Equipment: HOBAS pipes may be cut using a gasoline, air or electric powered disc cutter. A masonry (aluminum oxide typical), diamond tipped or other suitable abrasive cut-off saw blade could be used. If in doubt, seek advice from: H-OBAS PIPE uSA 800-856.7473 1. Mark the pipe circumferentially. Measure from a square end making sure that the cutting mark is at a right angle to the main pipe axis. 2. Provide support to either side of the cut and the pipe as a whole, so that no part will drop during cutting. if the pipe has to be rolled during the cutting process, ensure that at least one-quarter of the circumference is intact; oth- erwise damage may occur when moving pipes. 3. if cutting insitu, it may be necessary to cut a hatchbox out of the top of the pipe and complete the cut from the inside, if full circumferential access is not possible. 4. Carefully cut along the marked line. Before completing the cut, check again the cut piece will not drop as the cut is completed. if the pipe does drop, delamination of the pipe wall may occur. in that case, a re-cut or repair may be necessary. 5. Check the following: a. The cut ends of the pipe are in good condition. b. There is no damage to the pipe. c. There is no delamination of the pipe wall. 6. Add the homing mark to the freshly cut pipe ends. (optional) 7. Mark all cut pieces of pipe with the pipe stiffness and pressure rating. 8. If a standard FWC coupling is to be used, then a slight chamfer (see chart below) should be make to the outside edge of the pipe. This is best done with an abrasive disc grinder. Diameter Depth in. Length in. Range Min. - Max. Min. - Max. 18" - 24" 0.080 - 0.150 0.165 - 0.330 30" - 36" 0.100 - 0.200 0.220 - 0.450 42" - 54" 0150 - 0.250 0.450 - 0.750 60" - 110" �-0--200 - 0.300 0.600 - 0.900 length l depth pipe wall T DOTE: This general cutting procedure is also appropriate for non-square cuts such as for miters, fittings, repairs, etc. Mark the pipe for the cut required and fallow steps 2-5. Attachment # 4 of: HOBAS Pipe Submittal for: Phase I Sewer System Improvements Hobas Pipe USA, Inc. Buried Pipe Design Analysis for 27 in. Sliplined Flush Reline Pipe at 14 ft. of Cover. Summaryof Erojecf lnformafion Job Name: Phase 1 Sewer System Improvements Installation: Grouted Slipline Installation with Flush Relining Joint Location: South Windsor,CT Engineer: Wright-Pierce -Summary of Project Conditions Nominal diameter of pipe 27 in. Minimum pipe stiffness 145 psi Depth of burial of pipe(height of soil column) 14 ft. r Depth of water table(relative to pipe) 14 ft. Live load&type HS-20 0.67 psi R Native Soil Constrained Molulus,M5° 3,000 psi (Assumed) r ,gSummaryTOf De"signAnalysis_/Results Actual Allowable Deflection,as percent of diameter 0.50 5.0 Max Wall Crushing,safety factor 37.11 5.0 Min Ring Bending strain,calculated deflection,% 0.04 0.62 Max Ring Bending Strain,maximum deflection,% 0.42 0.62 Max Constrained Buckling,safety factor 20A8 2.5 Min - .M MO Me- 27SL-14 Page 1 of 6 arg 8/1/2012 z- _Prolect_Conditions_and Assumpftons*** -= - Pipe Properties Nominal Pipe Diameter,D. 27 in. Outside Diameter of Pipe Barrel,OD 28 in. Outside Diameter of Joint,ODZ 28 in. Minimum Pipe Stiffness,PS 145 psi Minimum Total Wall Thickness,Tt 0.76 in. mimum Liner I MCKness, I L 0.04 in. ep o Shelf, shelf - 0.27 in. -- ep th of Gasketroove, ee 0.14 in. UftL-omp reng a, 10500 psi oop Flexural o Pipe, hf 90E+06 psi Installation Conditions - Soil Weight,Ws 120 Ib/ft3 Water Weight,W. tjbjft3Soil Cover Depth,Hs Live Load Load,LL(at pipe depth) 0.67 psi Live Load Type HS-20 Water Table Depth,H. 14 ft. _ Assumed @ Grade Native Soil Constrained Molulus,Msn 3,000 psi (Assumed) —(Native Material) 27SL44 Page 2 of 6 arg 8/1/2012 Factors and Coefficients Bedding Coefficient,K..................................................... 0.083 (Grouted Annulus) (degree of support provided by soil) Pipe Shape Factor,Df............................................... 3 (relates pipe deflection to strain) Deflection Lag Factor,DL................................................. 1 (Max load-full soil (to compensate for the load increase with time) column used) Minimum Load/Safety Factors Maximum Recommended Deflection,%.......................... 5.0 Minimum Wall Crushing Safety Factor................... 5.0 Minimum Ring Bending Strain Safety Factor................... 1.5 _ Minimum Constrained Buckling Safety Factor................. 2.5 Minimum Pushing Capacity Safety Factor.......................-1 3.0 Pipe Geometry Outside Diameter,OD................................................ 28 in. Mean Diameter,D................................................... 27.28 in (O.D.-Tetr=Dm) Mean Radius,Rm........................................................ 13.64 in. (1/2 of Dm) Total Wall Thickness,Tj........................................ 0.76 in _-Liner Thickness,TL............................................... 0.04 in Structural Wall Thickness,Tstr.......................................... 0.72 in (T.=Tt-TO Nominal Interior Diameter,I.D......................................... 26.36 in 27SL-14 Page 3 of 6 arg 8/1/2012 Y 1 Pipe Stiffness (at 5%deflection) per ASTM D2412-92 Hoop Flexural Modulus,Ehf 1.90E+06 psi Structural Thickness,Tv 0.72 in Mean Radius,R. 13.64 in P.S. = Ehf X 11(149 X Rm) 1=Tw 112 = Ehf X T /(.149 X Rm X 12) Rm(5%)=Rm X 1.025 = Ehf X Tsfr /(.149 X(1.025R )3 X 12) 145.12 psi Loads Soil Weight,Ws 120 pcf Water Weight,W. 62.4 pcf s Soil Cover Height,Hs 14 ft. Water Table Height,HW 14 ft. Soil Load,La = Ws X H51144 11.67 psi Water Load,L. = %X Hw/144 6.07 psi Live Load,LL = HS-20 0.67 psi Rw = Water buoyancy factor RwI 1.0-.33Hx,1 Hs 0.67 Total Load = LS(RW)+LW+LL 14.55 Ipsi Wall Crushing Compressive Strength,Sae 10500 psi. Structural Thickness,Try 0.72 in. Outside Diameter,OD 28.00 in. Total Load,TL 14.55 psi i Capacity = Sa.X T& 7560 lb/in Load = (OD/2)(Total Load) 203.70 1bM - F of S = Capacity/Load _ = 37.11 >5 O.K. 27SL-14 Page 4 of 6 arg 8/1/2012 Deflection Deflection Lag Factor,DL 1 Bedding Coefficient,K. 0.083 Minimum Pipe Stiffness,PS 145 psi Soil Load,4 11.67 psi Live Load,4 0.67 psi Native Soil Constrained MOIUIUS,Mm 3000 psi Deflection L,) .149PS+.061 MS <5%OK --_ Bending Strain (corresponding to calculated deflection) Pipe Shape Factor,Df 3 Total Thickness,T, 0.76 in. Mean Diameter,Dm 27.28 in. Calculated Deflection,Defl 0.50% eb = D,(Defl)(Tt/Dm) 0.04 %<.62%OK - -__- Bending Strain I J(correspon,.Iinglo max allowable deflection) _ Pipe Shape Factor,Df 3 Total Thickness,T, 0.76 in. Mean Diameter,Dm 27.28 in. Max Recommended Deflection,Defl 5.00 % eb = DADefl)(Tt/Dm) - = 0.42%<.62%OK Buckling - - - - M Native Soil Constrained Molulus,Msn 3,000 psi -_ Minimum Pipe Stiffness,PS 145 psi Rh = 11.4/(11+(Dm)/(Hj(12)) = 1.021 Critical Buckling = (0.267)(PS)-3(Mj- (Rh) Q 298.021 psi Total Buckling = R„,(Soil Load)+(Hydrostatic Load)+(Live Load) Q, = 14.55 psi FofS = Q"/Qt = 1 20.48>2.5 O.K. 27SL-14 Page 5 of 6 arg 8f1/2012 Maximum Pushing Load Outside Diameter of Pipe,OD I 28.00 in. Structural Thickness,Tsu 0.72 in. Depth Gasket Groove,Dgg 0.14 in. Depth Shelf,Dsheg 0.27 in. - Axial Compressive Stress,Sa, 10500 psi Factor of Safety,FS 3.00 Tstrgg-Tsir-Dgg -D shelf Structural Thickness Under Gasket Groove,Tnr gg 0.31 in. {Dm gg=OD-2(Dgg)-2(Dshett)-Tsu gg) — - Mean Diameter Under the Gasket Groove,Dm gg 2 i.87 in. Allowable Capacity= (Dm gg)(Pi)(T Bugg)(Sac)/F.S. _ _ = 91590116 46 US Tons Since Ail Checks are O.K.The Design is Acceptable and Appropriate. 27SL-14 Page 6 of 6 arg 8/1/2012 M Attachment # 5 of: HOBAS Pipe Submittal for: Phase I Sewer System Improvements Exponent E-1po Jeff io85o Richmond Avenue Suite 175 _ Houston,TX 77042 telephone 832-325-5700 facsimile 832-325-5799 To:Kimberly Paggioli,P.E. www.exponent.com moo HOBAS Pipe USA 1413 E.Richey Rd. 04 Houston,TX. 77073 04 Exponent Project#: 0804146.000 Report Date: July 28,2008 Description: WRCT—SD#1 60"Joint Qualification Test 76 SCOPE 200 Exponent was hired to act as an independent observer for the project noted above. The purpose 04 of the project was to verify that the end joint design would not leak under external hydrostatic pressures up to 100 psi. The pipe tested was a 60" nominal pipe, specifically fabricated for this test, and identified by HOBAS' production number 080702-101. The following test protocol and procedure was set forth by HOBAS "Joint Tester Equipment Specifications and Test Procedure" (Attachment#1) TEST PROTOCOL AND PROCEDURE The first phase of our involvement was to verify the end joint dimensions as detailed in a HOBAS production drawing for pipe and end joints of this type. The pipe was initially made to an approximate length of 20 ft., with each end of the pipe having the fabricated ledge and groove design as indicated on the drawing. Each end was designated as A or B by this inspector, and initialed. Measurements of the end joint configuration and pipe dimensions were taken using instruments such as calipers, depth gauges, and circumferential tapes. All measuring instruments bore current calibration verification labels. Dimensions of the depth and length of the joint configuration of the end, ledge and groove were taken at two opposite locations around the circumference, or 180' apart, to confirm uniformity, noted as Location 1 and Location 2 in the dimensional tables provided later in this report. All of the items measured met the dimensional requirements found in the HOBAS Joint Tester and End Dimension Drawing (Attachment #2). Photographs were taken during each phase of the assembly and testing, and begin with the end joint configuration(Attachment 0). ago One EPDM gasket used to create the seal under the sleeve for the upcoming hydrostatic test was measured to verify that it conforms to HOBAS Drawing No. HOB-400-004-BX, "X Large moo Relining Gasket—Finned" (Attachment#4). so ao ` HS08041A8.000TW01 I .0 The gasket production markings were HK 1720 EPDM Job No 2-4715 07105, as produced by Hamilton Kent. The gasket was measured for height and width, at two opposing locations around the circumference, and found to be in compliance with the dimensions specified in Attachment#4. The first measured gasket was then installed on end A of the test pipe. The thickness of the fiberglass and resin sleeve that is to be used to complete the joint was also measured at three locations around the circumference. The sleeve was inserted on to the same end A. Photographs were taken to indicate the gasket markings and installation of one gasket and the sleeve. The gasket compression calculated for this test pipe was 50%. This was determined by HOBAS' gasket compression calculations, which were reviewed and verified (Attachment#5). The pipe was then to be cut into two approximately 2 ft. lengths, from each end, to allow for greater ease in handling and to get the shorter sections of pipe into the hydrostatic test chamber. Upon our arrival on the second day of the project, the two shorter lengths of pipe, ends designated as A and B, were photographed. The second gasket required for the seal was measured and found to be in compliance. This gasket was installed onto end B of the test pipe. End B was then inserted into the sleeve,providing one coupled length of test pipe, consisting of previously designated end joint configurations A and B, two HK1720 gaskets, and the HOBAS provided outer fiberglass sleeve. An external hydrostatic joint tester, provided by Plug-It Products, was placed on the outside of the test pipe and the entire assembly was placed in the hydrostatic test room in the Quality Control Laboratory at HOBAS. t Day 3 of our project at HOBAS consisted of performing the hydrostatic tests in accordance with I the "Joint Tester Equipment Specifications and Test Procedure". The external joint test frame, supplied by Plug-It Products, was centered over the pipe joint. This was confirmed by measuring the width of the test frame, and placing marks on the OD of the test pipe half the frame width on either side of the joint. The bladder seals were located beyond the joint axial limit, meaning the joint was fully exposed to the external pressure. The bladders of the test frame were pressured up to near 150 psi using air. Observation of the bladder pressure gauge on w the control panel of the test equipment showed the bladder pressure to remain constant. The .w; cavity between the bladders was filled with water, until all air was removed from the cavity. The outlet port for this cavity was closed, creating a sealed water bath around the external circumference of the pipe joint. The water pressure within the cavity was increased until a 'J sustained water pressure of 100 psi was reached, again confirmed by close observation of the r; pressure gauge on the hydrostatic tester control panel. The 100 psi water pressure was maintained for 15 minutes, with no resulting leaks found in the joint. Photographs were taken of the test assembly before and during the testing. Additional photos were taken from inside the Now pipe after the 15 minute test duration to further demonstrate that the joint design and MAI configuration would successfully maintain the hydrostatic pressure. _ f - HS0804146.0007W01 2 "' A second hydrostatic test was performed with an induced angular displacement arrangement. A 1 1/8" (1.125") minimum displacement was proposed. A small pipe block was placed in the joint at one location of the pipe ID. A photograph was taken showing the actual displacement to be 1.1265" at the pipe ID as recorded on the digital display of a dial caliper. This calculates to an actual angle of 1.125° (arctang (gap/ID)). The bladder was once again supplied with air pressure to a maintained pressure of near 150 psi, followed by the external cavity being filled ® with water until a pressure of 100 psi was reached. This duration of this test was also 15 minutes, during which close observation of the control panel pressure gauges indicated no loss of pressure or resulting leaks at the pipe joint. Photographs were taken of the pipe joint from inside the pipe after the 15 minute test to confirm no leaks occurred. CONCLUSION The proposed joint successfully passed a 100 psi external pressure test in both a straight and displaced alignment of 1.125°. ® Terry P. W A Test Specialist HS0604146.000TiA701 3 •g,TM TW sun ' Management Service CERTIFICATE The Certification Body of TOV SOD Management Service GmbH certifies that HOBAS° HOBAS PIPE USA 1413 East Richey Road 77073-3058 Houston, TX USA has established and applies a Quality Management System for II Development, production, sales and customer service of Centrifugally Cast Fiber-Reinforced Polymer Mortar(CCFRPM) Pipes An audit was performed, Report No. 70772724 Proof has been furnished that the requirements according to ISO 9001:2008 are fulfilled. The certificate is valid until 2014-02-01 Certificate Registration No. 12100 40115 TMS ir - yZ l rjY(t o� s 1,151 Munich,2011-02-08 QMS TGA-ZM-07-92 a co r TUV SOD Management Service GmbH+Zertitizierungsstelle•Ridlerstrage 65+80339 Munchen•Germany T13♦/�