Loading...
The URL can be used to link to this page
Your browser does not support the video tag.
Home
My WebLink
About
SWP273529(9)
(�rwAa L, d r W Q N 2 41 Ln Z OC W N w O Z e a w w a O r- F = p W O W ir�i LL No"' t� Oo Z W Q O Z aF� �� t9a I� Z n a v W (x N z (� w z o F Z a Z p � W WLLJ Q a N Q O C M J 0 O uO Q U CV a `Y' a 1�I - -- ---- - O LU C14 W NN 0 co O O 0 0 o 0 o 0 m O O N w J I. cV "ou o= a 3 0 Eo a o o m c v 0 a f D <" o o, 0 0 o -2 U` v n " o o a-°U1a°o Ncq 0 U aV2 ") w a-o Daniel W Carey From: Daniel W Carey Sent: Thursday, December 08, 2011 3:23 PM To: 'Phipps, Shannon' bject: Lake Ave: 36" lid - Use 1/2-inch Slot Grate achments: 15801VI2 DI ADA Grate.pdf Hi Shannon, Go ahead and order the 1/2" slot size, 1580M2. I'm not comfortable with the 1 1/2 inch width in the parking lot. Seems like a trip hazard, potential for high heels to go thru, keys and pens can easily fall thru. We'll pay for the cost using BI-42 Minor Changes. Thanks, Daniel Carey City of Renton, Surface Water Utility Phone: 425-430-7293 FAX: 425-430-7241 Email: dcarey@Rentonwa.gov From: Phipps, Shannon Lmailto:shannon p@jwfowler.coml Sent: Thursday, December 08, 2011 2:05 PM To: Daniel W Carey Cc: Pierce, Tom; Nolen, LaRue Subject: RE: 36" lid - Slot Width Daniel, They do have one of these with 1/2" slots. Looks like 6-8 weeks out and $475.00 me know. i nank you, Shannon Phipps Project Manager James W. Fowler Company 12775 Westview Drive Dallas, OR 97338 Office: 360-355-9045 Mobile: 360-239-7320 From: Daniel W Carey [mailto:Dcarey@Rentonwa.govl Sent: Thursday, December 08, 2011 11:05 AM To: Phipps, Shannon Cc: Pierce, Tom; Nolen, LaRue Subject: RE: 36" lid - Slot Width Shannon, Re -verify the open slot width. If I read the pdf detail drawing correctly it shows the slot width as 1 1/2" Typ. prefer a —1-in slot, which is the standard grated slot width. Thanks, DC From: Phipps, Shannon [mailto:shannon p@jwfowler.coml nt: Thursday, December 08, 2011 10:49 AM : Daniel W Carey Cc: Pierce, Tom; Nolen, LaRue Subject: RE: 36" lid i 8 1 — 2 31 3 2 34" HDPR I—ILI-11 himes NV Foafler Co. olkyFike General Contracturs r Irr. Act-tpkA. �C-- Submittal Transmittal Submittal No. S021 Date: 09/14/2011 Lake Ave S/Rainier Ave S Storm System Project To: I Daniel Carey —From: I Shannon Phipps —James City of Renton Co.:Co.: T VV. Fowler Co. WE ARE SENDING: Z Attached ❑ Enclosed F-1 Under Separate Cover Via: THE FOLLOWING ITEMS: Z Submittals El Product/Data El Samples [:1 Plans ❑ Shop Drawings ❑ Copies F Specifications F-1 Contract El Other: TRANSMITTED AS CHECKED BELOW El For Approval Z For Review and Comment El For Your Use ❑ Per Your Request E] Other: Copies Spec Section Description of Product / Data Subcontractor / Supplier 1 9-05.23 S021 - BI 23 & 32 34" HDPE Snap Cite Pipe James W. Fowler Co. REMARKS: NO EXCEPTJC!M�W Vji�WRJ REJECTED 0 REVISE AM,) REST SUBMIT SPECIFIED ITEM 0 SEE ATTACHED COMMENT SHEET DATED Clit :v'ANG IS ONLY FOR GENERAL CONFORNRIANCE WITH THE DESIGN CON- CE!V Cr ", HE FROJECT AND GENERAL CEWITH THE WFOPMATION IN THE CONTRACT NNIAITNTS. ANY ACTION SHOWN IS Si,19JECT TO IF,E REQUIRWENT$ OF HIE FLAI-413 AND SPEC!FICATIONS. CONTRA'.-IOR IS RE '�POA $ISLE FOR: DIVIENS-10W, WHICH WILL BE CONFIRMED AND COP: RFJL- A 11 t,,T THE JOB SITE, FABRICATION PROCESSES AND TECHNIQUES OF CON- TT'N J(, T ION, COC)RDINATION OF HIS WORK WITd rKAT OF ALL OTHER TRADES. -! T- � 4T,'SFACIORY PERFORMARCE OF HIS WORK. 14_ CORRECTIQNS N��TED •`�1 p EXCEPTION TAKEN d MAKE REJECTED 13 REVISE AND RESUBMIT Q __ SUBMIT SPECIFIED ITEM 11 SEE ATTACHED COMMENT SHEET DATEQ CHECKING IS ONLY FOR GENERAL CONFORMANCE VtITH THE DESIGN CO - f EFT OF THE FRS `c �T ►"� rr-tsrC?f'I CEP FLIAh'CE trstlTH THE INFORMATION Introduction n st c !S Stu—jr-c TO C'1'FIF` IN' THE CRSTIA F 714 08 Stdndiird S�e�f 8ation for ri Snap-Tite" HDPE Pipe, sold and d' .P I eAWITpe (PE) Pip0��LR=PPi 04 &on' UNTR v,T`� . IS UIREt1 p ride Diameter, This standard is used for ! AND Cf' a 1- by ISCO industries, I_LC, offers a comptateSIBLE F ,6 package of sales and support to reh ' it bst large diamQter IIDPE ptpe fu' to 63 } . lit;ES OF �.f ' failing culverts throughout the US. �� E `N� applications ° „ t=rs-p T1.r r- 4 ft OTHEi TR E1 S 1-800-CULVERT or visit www.cuiveri-rehab. ''' r.,ASTM D 2321-d5 Standard Practice for Under- com for all your culvert lining needs. ,. ; = ' groc:nd Installation of Thermoplastic Pipe for II ors and Other Gravity Flour Applications. Some of the characteristics of o f� -� 'STM F 585-94 Standard Practice for Snap-TiteO Solid Wail HDPE Pipe are:-__. Insertion of Flexible Polyethylene Pipe into Economical Flexible Existing Sewers Corrosion Resistant Mechanically Joined ASTM D-3212 Standard Specification for Hydraulically Smooth Strong and Ductile Joints for Drain and Sewer Plastic Pipes Long Design Life weather Resistant Using Flexible Elastomeric Seals Tappable impact Resistant Chemically Resistant Freeze Resistant Easily Installed Durable Small to Large UWTteters Abrasion Resistant Non -Toxic Inert Ligh1waight Listed and Approved Reliable Important Standards for High Density Polyethylene (HDPE) Pipe Standards important for Snap-Tite HDPE pipe relate to the resin the pipe is made frorn-and the standards related to manufacturing sizes and tolerances. ASTM Standards: ASTM D 3350-06 Standard Specification for Polyethylene Plastics Pipe and Fittings Materials" This standard defines the physical properties of the resin that the pipe is made from. Industry Standard for Culvert Refining: AASHTO M 326-08 Polyethylene (PE) Liner Pipe, 300-to1600-mm Diameter, Based on Controlled Outside Diameter Specifications for HDPE Pipe The physical properties of high -density polyethylene pipe are described using ASTM D 3350-06. New high performance bimodal resins, PE 4710 resins, have higher PENT test values. Slow crack growth properties can now be defined using eight values. As of December 2006, most HDPE pipe is made from resin with a cell classification of PE345464C. The pipe is labeled as PE3408/3608- The physical properties for PE345464C are listed in the chart below: id IMATION UNIT NOMINAL Material Designation PPI ! ASTM PE3408 / 3608 Cell Classification ASTM D 3350 345464C Density (3) ASTM D 1505 g/cm° 0.941 - 943 Melt Index (4) ASTM D 1238 gm/10 min 0.05 - .11 Flexural Mudulus (5) ASTM D 790 psi 110,000 - 140,000 Tensile Strength (4) ASTM D 638 I psi 3,200 j Slow Crack Growth i ESCR ASTM D 1693 hours in 100% >5,000 PENT (6) ASTM F 1473 hours >100 [IDS Cat} 7311 F (4) ASTM D 2837 psi 11,600 UV Stabilizer (C) ASTM D 1603 %C 12 - 2.5% The density fvovided is withcot carilcn black typical NDPF_ pipe has a density of.955 to .?57 with carbon black WWW.CULVERT REHAB.COM 1 (800) CULVERT tit - ,, , 41 t ;ea gg.s(� 'ze 40 • :O vNY' D O O M 1'- h �I:N r: v,th�2; ' ?.8,10 �y �.10 r• �- r •- r rir - rI ri maQ'4 M.M d TW N:1�'f r OI'Q{ iR CV to aOO. W N!N CJ N N M t'1 to tD (O 1O i M N N N m M N ,o N Cf M v> Jv) r n , w :0 T t•. m T L1 r Ir N c'1 N' tV tP Sp N M " M M' O O: aO eD n . �' N N f0 N t0 ro;6tO o o w'covs4 ; t4�cNv : N N N; '7 �i v I •p• N M';M•<+t!M tgiIA; ml✓n:M i t i r.{ rNi: t7 .- N (V.M M 49 N 'L SD-tp tC tb'tA NK,4 vv.MM:M 4 w tr, to N N m.�p ro M:MC� t n q 0 O T O�•aqap0 N N. ���:T mim�mW`fA O NiN WSfC'ODI r "• e' - N N: N; N;N}N: N' N N v:N l0; n h l tp tD N W O:n N:.4R'CCi ODO:cV'N (O 1D N:�NyiW aO yy•t9 '.M i f i , OD 00 h �- OD GD!MtM Ni�y149•�4N'ly 10 M.A�h t0tD•Uf: Oil mtp QO1QyWM IMnG:.� OM.O2 10N M "p'r- n e_ N NfA Cl) /.[�Cq. N-N ZCO t0 :- v v�V}n n#O.pE jiD t0; N1Fst t0 �L. cl':z O O'CD cv,n .- r r N CJ N-N'N N. Nr My M M M4•Y K tn:tn W.1p:lp rtCp } 3 : 1 nn O 41 m N ti C Q t6 p m C L p _ 3 m m a a m v a c li p „3 c »E`ms� �rWo�� >o�Eovm Uo 4i_75m c UPomCO jUA Ja=OM1tm q$�.0 �j. CL }= aCL o L o U p o (n C V O C c.:] m O y w'mc�.c-Cme m '' o m732—ac CO CC"o p 'D Si G 5i CO C wC' m< mfl UFG L_ inmc " c — rn W o msmG oc +v a �wrY"i�3 ve--m j H® D c m a s m c G i a is q M LLI 3 O U$ c m O N m J C. d-0 Z 9Y Q y fJ 0 0O u U =j a-, 5-5 qu `E c ='c LD iA lu OD S y > U• m d:d d 1 s� m n _ ' m' w Uli��tD.t% .'1. _ .cmm5mQ c02'u0 nmL os>aW oQa mmc2Dc0. .g°tGca �cm w mVI wffi� �� So-rnm i L _ • m m L 5 TL O. C IO r+ C L Lv1 L J= c E« $perp__«aso cmnrDamo L -? pm0 E?�3 3am1a y 4 r U C E) L a ymy .U. � Y n 'II O O — O ."T. =t 9 w L y O— :n ®` T O—D ro CCm QOi O'U"?_.0m b4• mVLmG„—}. •O ' :i �, i C c m' L 2 s °° 9 3 p D •m o p q G _ A M a u+ Tj C3 _ » E 41 Cd N _. W � Q U L � L OIL � iz cm U c CL O" Ny_'1 9 m ..: p•.a G F th C O 7 C O ._ ®@ C m S G C} N 4 C _O > G E C C yl tl U m U CII pp F r U O O Q• _ m `• c U D O m c `c«ou`ia �®cJvuL�•e �°oLL_c o, c°tEo�nQ u 0 o- u o w i a.E Q o c 3 0« 3 F � O o�� o�° :i o 0 iG a« o V c `�. ?= i SOtjnL'JPAH 2.11 Ease of Installation _ a D il Epp -] , �] a D �'- pD p�p�)) poa O' O C G- O O O d O O O O •. Q G J G V_pp M• N' O) O) n r9: M-IDS of Va' M n%O1: Mi ^ ,°{pI o Ct N M c% h .1 -1 ry m 7 C - O � N Ci- O N N vI- h.. m •, U) r1 r; r r (V`t`! N_CJ; c+.i. Y V' 1Ij� tA;h Om Q Q Q q R Q Q '.8rS 25 25 g o .9: g ��'2 d o .{i co ♦V CO �bp•gqq IS! 01 12 1 oo �r It N c0: o� M N_M h:e0 O n ;1 M VQ -rD_ R) o N O: (i! q� T; Dm_OGb)'MN. m ;t r N N N; tv m c7: M7• [O OS(11i s m eaoE 1D - Lg wQH C m o a d m ut�'Eornv) Ys�ar'=- �aLi'aa�`�� c y w v O � = f0 � CCp a 6 Pi p G �. L Y `-7 "� a �+ ^ 5 dl U° O= +. L C U L E O N >Sf .0 r - m s C .0 -'° °` :gym oo= •`°. Y m b V r o -y a Epp p „°, •G C a N 3 F a a c 'p p O D w U U E Lr C R O N] N adl D Y 9? m J m O y rn D O U t0 N C ry A° C G M L C i Ot p E C a y L 1. ip c u E aroc m w � r o a U o 01 r3 ,-°° le aOo a m� rn o g ®-^u :`u a�C°oo no 3E». md aNu�c=c :.s°o's cotO��.mS yv'4'ccm�arei NmQONL4 umaa2c °��tn a�a'cpmEc�a - •���mn» y`s wR�t 3 �N Ca .�� oawpmor.. v rcE t?.�In� c m m$ U3= mow°' 1=o��oro UD vEa a ti.36daoE=- 7• n' N m g a O C�o ac m rL 3r-t aoqu NaG -E-�w m cO) m��0 ac�ro°a °m C o r� °5!— C, c za m J 6 fl w°�L'�ida a •!: 1 m f71 3�(L [Ij a 4 « m ° _ram N a E r ° a M m cl a aca 2"o= U wo m o .:� �p C _m N Zt ^ 2 O .; w mSY ' o .� ° N '_� c a m air. o Gcj U Y.C.. W N S G' .O C W Z L N J 6 972 L NZ °D N Y C O Q ii W a i C . -L, Cl m a p- g a N_c E 4 U q '° C C 4 y Y O O C mnar�'� E :C i N N T t caN3°,�L�.a U 7 L O j ahem 91 rryd N C « s)mEco. - a do�ua a O m E V ccEm umoy m o a: { j 3 F N N :J o a F- u N j w E C�� °� a C a w4£r. a) g N O tef of m� Q = m .i L- U as y Q C C i N cat: :E @TAN g'3 G= y N O_ td 16 �N L° a x V ^Panes E C m°N W rn 5,.. c 0 id 16 532 n U01121123su110 Ss23 a Hydraulics 4 1U C C d b HSu R C 4 CM LL ro T n y Co. m rs y G � a C ,•sp h U . Nj M�b:f•_Ih tV N�mIC'1(v27!W_ff! fU.10 a IO} N -0 �h d Im to i 1 j ! E Wj�f�O. m3 Ni�W 4'S 0:tD : toN N: m-miv;7t ,tD, tO-W-M1 • I - ( I mipSW'h_M1ZofW, Go p M to Q : (a m an j i } 888'8888188Cc, '88888886 888i8j8i8'g181$ W tD : M CQ I O O 1 uJ m Mi M. M. ? h Nt N�^ 0�01O r='. NM !.M M t0 P) 0'. m:'m m-.- ((��, to t9 S N N-t�7-t0,V 11di = i S 8 `8 $:'8 0 0 8 8 (Die N` N @ oppp t I @�.W M M N-N ttVy N. t(yy co (o tD W,? �t m; W mt pO P= t V• O Q`G� i�•A ttVy �{pp N N: �-^ '.m 1� hf @ @}@ M3 m O? O• Q Sim 6J to . A- (1 M1 I m W O O- N N N M i tc ! `N:tV`N'od M 47 Y!,@ 96 W tV:^ m W. ; Q! O l+f , M O. W N t�l 4: tV}p) 1 !� r'!N co Q7?fttJlh tp'Vtof@t wlh h(N(W W_h.-.M1 �@ ,O h O' O 1 W. !•• 1 (it: Q t01 m} h (A G h m mj 7 O�p'O m M O) to i t0 �- O; •': Mi Ci7-O: t0• Wi O� O� N tV.N:N N NAM- QI K7 p: p; O�71 tD o.m'Q�f.@'t0:2;M7(n 1 ¢)I@@'AWN: N:a ? co -Kt: O;N N.W N N:N m.to M'c! ,Ni Nj W�@:7 �l!CJ: M+m a V.v}7•Iq IOio,wiw �1� N WINI M.to m c.) M ry ?'0S Q:1aDf bi mltGrtOjm�hlW f 7 q? sattneapAH 0 _4 rativp Flaw Rates for Concrete Pipe lined with Snap -rite® .. Culvert Size .. Concrete Size Aver. ID Flow Flow % of Flow j; 12" 10.75 10.06 438.00 448.00 102% 15" 12.75 11.94 794.00 706.00 89% 18" 14 13.10 1,292.00 906.00 70% 18" 16 14.98 1,292.00 1,293.00 100% 21 " 16 14.98 1,948.00 1,293.00 - 66 - % 91 % 21 " 18 16.87 1,948.00 1,770.00 ------------ 24" ---------------- 18 16.87 2,781.00 1,770.00 64% 24" 20 18.72 2,781.00 2,345.00 84% 240 22 20.59 2,781.00 3,023.00 109% 27" 22 20.59 3,808.00 3,023.00 79% 27" 24 22.47 3,808.00 -- 3,813.00 ---------- _ 100% 30" 24 22.47 5,043.00 3,813.00 76% 30" 28 26.21 5,043.00 5,752.00 _----.-.._- _ 114%° 36" 28 26.21 8,202.00 5,752.00 ----70% 36" 30 28.08 8,202 00 6,914.00 84% -- 36• 32 29.95 8,202 00 8,213 00 100% ----- 42" 32 29.95 12,372 00 8,213.00 66% 42' 36 33.70 12,372.00 11,244.00 91 % 9,581.00 42• 36 33.70 12,372.00 77% 48• 42 39.31 17,665.00 16,961.00 96% 54• 42 39.31 24,182.00 16,961.00 _70% 24,217.00 - -- 54• 48 44.93 24,182.00 100% -- 60• 44.93 32,031.00 24,217.00 76% 48 WE 54 50.54 32.031.00 33,155.00 104% 661 54 50.54 41,301.00 33,155.00 50,015.00 50,015.00 80% 121 96% 66' 63 59.10 41,301.00 72" 63 59.10 52,098.00 84" 78,577.00 50,015.00 64% 63 59.10 1181 WWW.CULVERT REHAB.COM 1 (800) CULVERT L- f ANIL v7PWashington State Department of Transportation Paula J. Hammond, P.E. Secretary of Transportation February 11, 2010 Mark Theetge Isco Industries LLC P.O. Box 4545 Louisville, KY 40204 Environmental and Engineering State Material Laboratory PO Box 47365 Olympia, WA 98504.7365 360-709-5400 Fax: 360-709-5588 TTY: 1-800-833-6388 www wsdot wa gov Re: Subject Matter Expert Product Evaluation, SME 20 10-011 Dear Mr. Theetge: The Washington State Department of Transportation (WSDOT) Subject Matter Expert for high density polyethylene pipe, states Snap Tite Culvert Liner System manufactured by Isco Industries LLC confornis to Standard Specification for Road, Bridge and Municipal Construction (2010) Section 9-05.23. He recommends that this product be listed in the WSDOTQualified Products List (QPL). A copy of the listing is enclosed. The acceptance code "CA" denotes that the product is "Conditionally Approved" and "2010" indicates that acceptance on the job will be verification by the field inspector that the Manufacturer's Certificate of Compliance is on file at the Project Engineer Office, and that the product submitted by the Contractor is the same as approved on the QPL page and is being used in accordance with the plans and specifications. The QPL is available on the Internet at: N,*,-%vw.Nvsdot.Nva.go,%,,Iblz/matsfqpi/qpi,c ftn. If there are any questions concerning this matter, please contact Steve Hughes at (360) 709-5442. Sincerely, Kurt Williams, P.E. Construction Materials Engineer KW/ sdh Enclosure cc: via e-mail B. Briggs - Assistant Construction Materials Engincer,Admin R. Molohon - State Materials Documentation Engineer J. Christianson - Hydraulic Specialist /All M. Theetge - Isco Industries LLC (m-,irk.theetge@isco-pipe.com) � Washington State Ask WASHINGTON STATE DEPARTMENT OF TRANSPORTATION j Department o1 Transportation QUALIFIED PRODUCTS LIST February 08, 2010 Contractor: Sub Contractor : Contract Number Date : Specification Reference - Material Category Reference No Accept. Code Last Update 9-05.20 Pipe - Corrugated Polyethylene - Storm Sewer Pipe and Joint Pacific Corrugated Plastic Pipe, LLC - Newport Beach, CA Bid Item # QtyVerified By Date Corrugated High Density Polyethylene Storm Sewer Pipe and Joint QPL 2006-157 CA 2010 1125/2008 Corrugated high density polyethylene storm sewer pipe with bell and spigot joint; 12-inch through 36-inch diameter Type S Polvtubes, Ltd - Arlington, WA Bid Item # Qty Verified By Dale Boss 2000 Polyethylene Storm Sewer Pipe QPL 2001-040 CA 2010 01/31/2007 Corrugated high density polyethylene storm sewer pipe: 12 inch to 30 inch diameter Specifications allow to a maximum of48 inch diameter but the manufacturer has only been approved for the diameters indicated. 9-05.23 High Density Polyethylene (HDPE) Pipe Isco Industries LLC - Louisville. KY Bid Item # QtyVerified By Date. Snap The Culvert Liner System SME 2010-01 1 CA 2010 02/08/2010 Solid wall pipe, smooth interior and exterior; Snap together water -tight joints; Maybe used as liner pipe (12-inch to 84-inch) and direct buried pipe (12-inch to 60-inch) 9-05.50(2) Precast Concrete Manholes Berg, Vault, Inc. - Mt Vernon, WA Bid Item # Qry Verified By Date Precast Concrete Manholes QPL 2006-1 l8 CA 5020 0820/2009 Manufacturers of precast concrete manholes; See Std Plan B-15.20-00, B-15.40-00, B-15.60-00 and B-30.90-01 for further details See Notes: (10) 125 __._. Chapter 0? Snap-TiteO High -Density Polyethylene (HDPE) Pipe WWW.CULVERT-REHAB.COM 1 (800) CULVERT C� r+ v y M O � (D P4. m (D Q 'U m Z3� (D 0 a •a W a C A s d 6 0. C (D Q i s t_Tt E) qJ e M C Introduction Snap-Tite" HDPE Pipe, sold and distributed by ISCO Industries, LLC, offers a complete package of sales and support to rehabilitate failing culverts throughout the US. Please call 1-800-CULVERT or visit www.culvert-rehab. com for all your culvert lining needs. Some of the characteristics of Snap-Tite® Solid Wall HDPE Pipe are: Economical Flexible Corrosion Resistant Mechanically Joined Hydraulically Smooth Strong and Ductile Long Design Life Weather Resistant Tappable Impact Resistant Chemically Resistant Freeze Resistant Easily Installed Durable Small to Large Diameters Abrasion Resistant Non -Toxic Inert Lightweight Listed and Approved Reliable Important Standards for High Density Polyethylene (HDPE) Pipe Standards important for Snap-Tite HDPE pipe relate to the resin the pipe is made from and the standards related to manufacturing sizes and tolerances. ASTM Standards: ASTM D 3350-06 Standard Specification for Polyethylene Plastics Pipe and Fittings Materials. This standard defines the physical properties of the resin that the pipe is made from. ASTM F 714-08 Standard Specification for Polyethylene (PE) Pipe (SDR-PR) Based on Outside Diameter. This standard is used for most large diameter HDPE pipe (6" to 63") Applications. ASTM D 2321-05 Standard Practice for Under- ground Installation of Thermoplastic Pipe for Sewers and Other Gravity Flow Applications. ASTM F 585-94 Standard Practice for Insertion of Flexible Polyethylene Pipe into Existing Sewers ASTM D-3212 Standard Specification for (�e� 4)5,90 1 Joints for Drain and Sewer Plastic Pipes Using Flexible Elastomeric Seals Industry Standard for Culvert Relining: AASHTO M 326-08 Polyethylene (PE) Liner Pipe, 300-to1600-mm Diameter, Based on Controlled Outside Diameter Specifications for HDPE Pipe The physical properties of high -density polyethylene pipe are described using ASTM D 3350-06. New high performance bimodal resins, PE 4710 resins, have higher PENT test values. Slow crack growth properties can now be defined using eight values. As of December 2006, most HDPE pipe is made from resin with a cell classification of PE345464C. The pipe is labeled as PE3408/3608. The physical properties for PE345464C are listed in the chart below: PROPERTYVALUE SPECIFICATIONNOMINAL Material Designation PPI / ASTM PE3408 / 3608 Cell Classification ASTM D 3350 345434C Density (3) ASTM D 1505 g/cm3 0.941 - 943 Melt Index (4) ASTM D 1238 gm/10 min 0.05 - .11 Flexural Mudulus (5) ASTM D 790 psi 110,000 - 140,000 Tensile Strength (4) ASTM D 638 psi 3,200 Slow Crack Growth ESCR ASTM D 1693 hours in 100% >5,000 PENT (6) ASTM F 1473 hours >100 HDB @ 7T F (4) ASTM D 2837 psi 1,600 UV Stabilizer (C) ASTM D 1603 %C 2 - 2.5% The density provided is without carbon black. Typical HDPE pipe has a density of .955 to .957 with carbon black. KO WWW.CULVERT-REHAB.COM 1 (800) CULVERT ZZ Types of Polyethylene Pipe All polyethylene (PE) is not the same. In ASTM D 3350-05, low density PE is defined as having a density range of 0.919 to 0.925 g/cc; P+ medium density has a range of 0.926 to 0.940 g/cc and high density is defined with a range = from 0.941 to 0.955. All densities are without �. carbon black. Density influences key properties in polyethylene materials. As the density increases, the tensile strength increases; N also chemical resistance increases. Slow Crack Growth C The PENT test is used to determine stress crack resistance for PE resins. The PENT test M is conducted in accordance with ASTM F 1473, "Standard Test Method for Notch Tensile Test '+C to Measure the Resistance to Slow Crack Growth of Polyethylene Pipes and Resins". �p This test uses a solid sample of material which _ is notched and tested. The PENT test is a good test of slow crack growth. Scratches and gouges can cause crack propagation. Ir) Materials with high PENT numbers are less -� likely to fail because of slow crack growth. 'a Traditional PE 3408/3608 resins have PENT tD test values of about 100 hours. WWW.CULVERT REHAB.COM 1 (800) CULVERT 11 Table 3-4 Comparative Flow Rates for Concrete Pipe lined with Snap-Tite° Based on Manning Equation n=.00914 for Snap-Tite , n=.015 for concrete, s=.001 Concrete Size Aver. ID Flow (GPM) Flow (GPM) % of Flow 12" 10.75 10.06 438.00 448.00 102% 15" 12.75 I 11.94 794.00 I 706.00 89% 18" 14 13.10 1,292.00 906.00 70% 18" 16 14.98 1,292.00 1,293.00 100% 21 " 16 14.98 1,948.00 1,293.00 I 66% 21 " 18 I 16.87 1,948.00 1,770.00 91 % 24" 18 ( 16.87 2,781.00 1,770.00 64% 24" I 20 I 18.72 2,781.00 2,345.00 I 84% 24" 22 20.59 2,781.00 3,023.00 109% 27" 22 20.59 3,808.00 3,023.00 79% 27" 24 22.47 3,808.00 3,813.00 100% 30" 24 22.47 5,043.00 3,813.00 76% 30" 28 I 26.21 5,043.00 5,752.00 114% 36" 28 26.21 8,202.00 5,752.00 70% 36" 30 28.08 I 8,202.00 I 6,914.00 84% 36" 32 29.95 I 8,202.00 8,213.00 100% 42" 32 29.95 I 12,372.00 8,213.00 66% 42" 34 33.70 I 12,372.00 9,654.00 77% 42" I 36 33.70 I 12,372.00 11,244.00 I 91 % 48" I 42 39.31 I 17,665.00 I 16,961.00 ( 96% 54" I 42 39.31 24,182.00 16,961.00 70% 54" I 48 44.93 24,182.00 24,217.00 100% 60" I 48 44.93 32,031.00 24,217.00 76% 60" I 54 50.54 32.031.00 33,155.00 104% 66" ( 54 I 50.54 41,301.00 33,155.00 80% 66" I 63 I 59.10 41,301.00 50,015.00 121 % 72" 63 59.10 52,098.00 50,015.00 96% 84" 63 59.10 78,577.00 50,015.00 64% 18 WWW.CULVERT-REHAB.COM 1 (800) CULVERT Installation Steps Step 1 — Select and prepare the existing culvert. Inspect the culvert to ensure the liner can be inserted without obstruction. Flush and/or clean the existing culvert. Culvert must kst be cleared of any objects that may obstruct the inserti+..rr of the finer. Pieces of wood are used to maintain grade and alignment WWW.CULVERT-REHAB.COM I (800) CULVERT Step 2 — Insert one end of Snap-Tite® Culvert Liner into existing culvert. This can be done using a variety of techniques. Leave about five feet of liner exposed. Prior to installation of first section, it may be necessary to create a "nose cone" by cutting the ends of the pipe. C'-n,& cnd of the ling is inserted into the cull ert. WWW.CULVERT-REHAB.COM 1 (800) CULVERT FM Step 3 — Position the next section of Snap -rite® Culvert Liner with proper alignment. Place the opposing end of a second section against the exposed end of the first section. The two sections must be in alignment and have the same slope. Tho r*xt si+ctkm is "with ft fkst. l F26] WWW.CULVERT REHAB.COM 1 (800) CULVERT Step 4 - Lubricate the male side of Snap-Tite® joint. A gasket is normally supplied with Snap -Titer pipe. It is installed on the male end to help make a watertight seal, and should be placed in the first groove. Make sure that one end of the gasket is touching the side of the groove that is closest to the end. Check the alignment of the gasket around the liner. Apply lubricant to the entire circumference of the liner. The lubricant must be applied evenly to reduce the chance of a torn or rolled gasket. Option: Mastic can be applied to second large groove to reduce chance of leakage when joints are deflected. Carefully apply mastic to large groove. Too much or too little mastic can increase chance of leakage. (See Drawing 2: Male End of Snap -Tice® and Completed Snap -rite Joint) WWW.CULVERT REHAB.COM 1 (800) CULVERT [27] Step 5 - Attach the chains and couplings. Double -wrap the chains approximately four feet from the coupling end and tighten with binders. Attach one come -a -long on each side of the couplings, 180 degrees apart. Chains and hinders are attach -ad and 28 WWW.CULVERT-REHAB.COM 1 (800) CULVERT Step 6 - Snap liner together. Align the ends of the male bevel inside the female bevel. Use a pry bar or move the come -a -longs to different positions on liner if pipe is out of round to improve alignment. Be sure male end has been properly lubricated. Pull the couplings together slowly, forcing the female end to expand and allow the male end to move into the female end. Apply force slowly and make observations. Apply force to one side until liner slightly deflects, then apply force on other side. Look for the female side to increase in OD as force is applied. aru'" Caution! If chain or come -a -long appears to be overstressed, stop operation! Quickly move away from the chain! When ends and grooves are aligned, the couplings will "snap" and lock together. Allow time for this to occur. If operation is stopped, check alignment. Often poor alignment or a stone or dirt in the end causes the need for additional pressure. Rotation of the liner will change alignment. Clean out the joint if needed. WWW.CULVERT-REHAB.COM I (800) CULVERT FO Step 7 — Push joined liners into culvert and repeat until completely lined. Remove chains, push joined liners into culvert and repeat steps 1-6. Each new piece of pipe is snapped onto the proceeding pipe and pushed into the culvert, leaving enough pipe protruding from the culvert to join with the next length of liner. Joir*d Ilkws wo that pud*4 ifo drs ed►%d Proco" is rop+ d WO $0 CWV44 is cOMWON b*4. WWW.CULVERT REHAB.COM I (8W) CULVERT Step 8 — Seal the culvert ends. Make an end seal for the annular space a distance of one to two feet at each end using an appropriate grout. A relatively dry cement grout is used in most situations. Chemical grout, oakum, and other seals are used depending upon the situation. See Chapter 6, Annular Space Grouting. Ends are sewed. Pipes are inseifO to drain any water. ter bent air andallow for grout Becton. Time anrxdar space is then gtoirted_ Grouting is sinQar to backfftng. as it pjoJdes support for the road and liner. WWW.CULVERT-REHAB.COM 1 (800) CULVERT Step 9 — Grout the annular space. It is recommended that the annular space between the existing culvert and the liner be grouted. This will help fill the voids created by previous washouts, provide additional structural support, and prevent point loading. See Chapter 6, Annular Space Grouting. Additional information is available by calling your Snap-Tite® representative. WWW.CULVERT-REHAB.COM I OW) CULVERT ��A- ,• 7 • Annular Space Grouting D c 0 WWW.CULVERT-REHAB.COM I (800) CULVERT 37 I -I C O L tU Ga M CL 0) L t0 75 G C Q 378 Purpose When rehabilitating culverts, the primary goals of annular space grouting are to stop the leakage of water, stop movement of road backfill materials, secure the liner in place and reinforce the old culvert. Grouting the annular space is a key process in reaching these goals. Proper grouting of the annular space insures a long life for the pipe system. This is critical for culvert rehabilitation. When the existing culvert has deteriorated to such an extent that bedding material has infiltrated into the culvert, leaving voids beneath the road base, grout can be used to fill these voids. This effectively stabilizes the surrounding soils and eliminates the potential for settlement or collapse of the roadway. The grout around the liner provides extra support. This support increases the collapse strength of the liner. After grouting the annular space, the liner is further reinforced, better resisting ground water collapse pressure. When old culverts begin to collapse, there is a danger of point loads and deflection. The old culvert may fail in a random fashion and create loads in the liner. The grout again supports the old culvert and prevents point loading. Need for Grout Not every slip -lined culvert requires grouting. If there is a small annular space resulting from the slip lining, and the host pipe is structurally sound, grouting of the annular space may not provide enough benefits to justify the cost and effort required. Additionally, injecting grout into a small annular space may require pressure injection which could cause joint leakage or damage to the Snap-TiteO liner. Concurrently, if the host pipe has failed or is in the process of failing, evidenced by corrosion of a metal pipe or joint separation of a metal or concrete culvert (box structure or pipe), then grouting a slip -lined culvert is recommended. WWW.CULVERT-REHAB.COM I (800) CULVERT Types of Grout Grout has traditionally been defined as "a thin, coarse mortar used for filling masonry joints." In recent years the definition of grout has been expanded to cover a wide range of concrete and organic compounds used to fill masonry joints or space in or around pipes or liners. In Snap-TiteO culvert lining applications, both non -cellular and cellular grouts can be used to fill the annular space in a rehabilitated culvert system. Non -cellular grouts are the traditional Portland cement formulations, typically referred to as flowable fill. These products are well known and are used for many applications, including grouting liners in place. The department of transportation for most states has some type of specification established for flowable fill grout. Flowable Fill Grout This is comprised of a mixture of cement, sand, and water, sometimes with chemical admixtures put in to affect certain properties of the grout mix. A portion of the cement component can be replaced with Fly ash. Fly ash is a cementitous material, usually at a lower cost than cement, which can improve certain properties of the resulting grout mix. Fly ash may not be available in all locations. Flowable fills are sometimes used to fill the annular space or as backfill around pipe. The unit weight, or density, of a flowable fill grout mix typically ranges from 90 to 140 pounds per cubic foot (pcf). Project specifications may call for a 3-sack, 4-sack, or 5-sack flowable fill, referring to the amount of cement added to each cubic yard of the grout mix. One sack of cement weighs 94 pounds. Thus, a 3-sack mix will have 282 pounds of cement mixed into each cubic yard batch; while a 5-sack mix will include 470 pounds of cement per cubic yard. The extent to which a flowable fill grout can travel within the annular space is limited. An annular space within a culvert that is longer than 40 — 50 feet may not be completely filled with such a grout mix. In such applications, by lowering the density, or unit weight, of the grout mix, the flowability of the mix will typically increase. Certain chemical admixtures are available to reduce the density of a flowable fill grout mix. The grout unit weight may be lowered to a value in the vicinity of 100 pcf, depending on the type of sand, fly ash, and cement used and the percentage of the various components in the mix design. These admixtures are discussed in depth in the admixture section of this chapter. Cellular grout is a low -density grout mix comprised of cement and water (or cement, fly ash, and water) with a foaming agent added to inject a large volume of macroscopic air bubbles into the grout mix. This admixture greatly reduces the density, or unit weight, of the grout mix. To produce cellular grout, a concentrated foaming agent Is required, in combination with various types of foam generating equipment. This equipment may generate foam via air pressure or water pressure. These air bubbles stay in suspension long enough for the cement paste to coat them and begin to hydrate, or "set." Once hardened, the grout mix has a compressive strength that can range from 200 psi to well over 1,000 psi. These values are higher than that of the bedding soil that was originally around the host pipe. Soil compressive strength values are typically not considered in a pipe system; what is desired is the density of the soil or fill material. Cellular grouts can be designed to have wet densities, while still in the "plastic" stage, ranging from 30 pcf to 80 pcf. With this lower unit weight the material is able to flow long distances within the slip -lined pipe system and flow through the holes or separated joints of the host pipe, filling the voids in the bedding soil around the failed host pipe. These voids were originally caused by the soil infiltrating into the host pipe through separated joints or holes in the pipe. The voids are thus filled with the grout flowing through these same openings. Grout Properties Density or Unit Weight The density of a grout mix is the weight, in pounds, of a defined volume of the grout, that being one cubic foot of material. It is reported in units such as "pounds per cubic foot (pcf)." The unit weight is measured by collecting a sample of the grout mix and filling a container of a pre -determined volume. Typically a one- half cubic foot metal unit weight bucket is used. After completely filling the bucket and striking off the surface, the bucket is weighed. The weight of the empty bucket is subtracted from this value and the resulting number is multiplied by two (using a one-half cubic foot bucket) to obtain the density of the grout mix (pcf). WWW.CULVERT-REHAB.COM 1 (800) CULVERT 39 M 0 Air Content The air content is the amount of air included in the grout mixture; this is reported as a per- centage of the total volume. Certain chemical admixtures have the ability to entrain air around sand particles in the mix. These are microscopic air bubbles and typically add 3-5% of air to the mix. The advantages of having air bubbles in a grout mix are that they provide for better flow of the material as well as giving greater resistance to the damaging effects of a freeze/ thaw environment. There are other chemical admixtures that trap larger air bubbles in the grout mix, injecting up to 70% air into the total mixture. These air bubbles are attached to the cement particles in the grout. The resulting grout mix can appear to have a foam consistency. The larger air content in the material greatly enhances the ability of the grout mix to flow longer distances and through smaller spaces. The viscosity is the thickness of a liquid or "a measure of a fluid's resistance to flow." A low viscosity is desirable for grout mixes in a Snap-Tite® application. The viscosity of a grout mix is measured by use of a flow cone. A slump test is not applicable in determining the flow of a grout mix. Compressive Strength The compressive strength of grout is the amount of compressive force that the material can resist after the grout material is allowed to set. This is determined by obtaining a grout sample and filling a cylindrical container, typically a mold 2" in diameter and 6" in height, and testing the sample in a compressive strength test apparatus. This test is conducted in pre -determined time increments, such as at sample ages of 1-day, 3-days, or 7-days after the grout mix is batched. While this material property is commonly specified for concrete and grout used in other applications, this is not an important property for grout used to fill the annular space after slip lining a culvert. Practically any grout used will have compressive strength values greater that the original soil surrounding the host culvert. The significant property of the grout mix is the density of the material. WWW.CULVERT REHAB.COM 1 (800) CULVERT Applications & Grout Selection Snap-TiteO liner is used in a variety of culvert and gravity flow pipe applications. There are many types of grout available. A thorough analysis of the existing culvert pipe is needed before making liner and grout selections. Engineering analysis may be required. The condition of the pipe to be lined is im- portant in determining the liner and grout requirements. Grout will fill the space between the liner and the pipe and assist in maintaining a pipe seal. If the existing pipe has lost its ability to handle soil and highway loads, a liner and a grout must be selected to handle these loads. In most situations, a liner with a DR of 32.5 and a low -density foam grout with unit weight values of 40 pcf and greater will be suitable. If the host pipe is in good condition, i.e., without corrosion holes or separation of the pipe joints, then grouting of the annular space may or may not be needed. In this application, the remaining site conditions should be evaluated to determine the advantages and disadvantages of grouting. Length of Host Pipe The length of the pipe is a very important consideration when grouting. If the host pipe is short, i.e., less than 60 linear feet in length, almost any mix discussed can be used as long as low pressure is utilized for installation. Availability and economic factors play a larger role in grout selection in these applications. Elevation can be used to provide pressure for grouting short runs of pipe, depending upon the flow rate of the grout. As the length of pipe increases, the amount of pressure required for grouting the annular space increases. Volume of Annular Space Annular space is the area between the liner and the existing pipe. If there is only a small space resulting after slip lining Snap -rite® into the existing pipe, it will be more difficult to fill this space compared to a slip lining situation where a large annular space is the result. More pressure may be required to fill a small annular space compared to a larger annular space. The density of the grout should be reduced as much as possible to reduce the risk of damage to the liner during the grouting operation. When the annular space is small, a high flow, low -density grout under low pressure (less than five feet of head or 2 psi) will fill this space. Portland cement grouts containing fine aggregate, such as coarse sand, often require higher pressure than is desired to flow the length of the pipe. If this type of grout must be used, it is recommended that multiple grout insertion pipes are placed at various lengths within the annular space. This will lower the force required to place the grout within the area. If there is a large difference between the diameter of the liner and the existing pipe, a grout with a higher density will apply more pressure to the liner during and after installation. A lower density grout is preferred in this situation as well. Flotation Why is flotation a concern? During the grouting operation, a pipe may float in the grout material and rise to the top of the host pipe. This may change the grade of the liner, affecting the water flow through the lined pipe. There are numerous methods that help control this problem. One method is to attach wood, plastic or metallic blocks inside the culvert, along the top of the host pipe or the liner itself, to minimize the flotation. This technique is also referred to as bridging or blocking. Runners attached to the bottom of the liner are also used to center the liner. Table 6-1 Density Failed or Range {pcf) Good Failing 3-Sack Flowable Fill 1 90 —140 Reduced Density 70 —120 Flowable Fill Cellular Grout 140 — 80 Grouting the liner in lifts will minimize a potential flotation problem. Sand bags, or other materials, can be used to weigh the liner down and counter the buoyancy factor to prevent the liner from floating. Elevation Change When there are large changes in elevation between the ends of a pipe being lined with Snap-Tite'0, the grout may exert additional pressure on the liner material. When the elevation difference is greater than five feet, the method of grout installation must be evaluated to prevent collapse of the liner. Grouting in lifts is usually the best method to prevent liner collapse and other problems. Elevation, or gravity, can be used to provide pressure for grouting short runs of pipe, depending upon the flow rate of the grout. As the length of pipe increases, the amount of pressure required for grouting the annular space increases. Culvert Circumstances The specific culvert circumstances have the greatest impact on the type of grout that should be used to fill the annular space. Table 6-1 is provided to assist in this determination. This is an aid only; it should not be considered a definitive recommendation of what type of grout to use for any particular application. < 50 50 —125 > 125 I Light Heavy Traffic Traffic x x x x x x x WWW.CULVERT REHAB.COM 1 (800) CULVERT 41 I ►! Grouting Operation Preparation The preparation for the grouting operation begins before installing Snap-Titee pipe into the existing culvert pipe. The existing culvert should be inspected to determine the following factors: ■ Point of entry for grout • Length and slope of culvert • Existence of corrosion holes or separated joints in culvert Point of Entry for Grout There are many ways that grout can be placed into the annular space of a rehabilitated culvert. It can be pumped in, under low pressure, or allowed to flow in by gravity. This can be done through injection ports placed through the bulkheads or through a hole or holes cut into the top of a metal culvert pipe, behind the bulkhead. The grout may flow into the annular space though these holes, on one end or in both ends of the culvert. In the instance where a culvert extension is planned along with the pipe rehabilitation, the ends of the Snap-Tite° pipe can be blocked, a coffer or earthen dam built around the pipe 1 ! i 42 7 WWW.CULVERT-REHAB.COM 1 (800) CULVERT L_. extension and grout is placed into the area, flowing through the annular space created by the slip -lined culvert. Length and Slope of Culvert Elevation is normally used (provided there is less than a 10-foot elevation change) to provide pressure for grouting short runs of pipe up to 60 to 80 feet in length, depending upon the flow rate of the grout. As the length of pipe increases, the amount of pressure required for grouting the annular space increases. Measure the elevation change and the total distance between the inlet and the outlet and determine the total length the grout must flow. This information will help in the selection of the grout and the method of grout injection. Existence of Corrosion Holes or Separated Joints If either of these factors are observed during the culvert investigation, the possibility exists that there are voids in the soil bedding around the original culvert structure. An additional volume of grout will be required, beyond the F x A 4 calculated annular space volume, to fill these voids. An estimation of this additional volume (10%, 20%, etc.) should be made at this point :. 1. As discussed before, flotation of the liner is of concern when a liner is to be grouted or there is ground water present. To prevent flotation, using blocks or skids around the pipe can center the Snap-Tite® culvert liners. Blocks or skids are typically installed in a staggered pattern. Spaces are left between the blocks or skids to allow grout to flow under and around the liner. Blocks are installed in the top 120 degrees of the culvert. For culverts 48" in diameter or larger, blocks are attached to the old culvert. The first block is installed, and then a space is left before the second block is installed. Space must be left for grout insertion tubes. These blocks are usually four to eight feet in length. The thickness is determined by the difference in the ID of the culvert and the liner. The upper skids must have structural strength adequate to resist the buoyant force created as the liner is grouted in place. Wood and solid plastic will work. Styro- foam does not have adequate compressive strength to work for many liner sizes. To prevent the Snap-Tite'O liner from moving off -center during the grouting operation, grout may be placed in a staggered sequence, using multiple grout injection points on each side of the liner. This will help assure an even distribution of grout on both sides of the Snap-TiteO pipe. Before specifying blocking, verify the condition of the culvert. Severe deflections up or down can reduce the opening and prohibit slip lining. If this condition exists, blocking may not be possible. Every jobsite is unique and must be evaluated. Vent Ports Vent ports should be located at strategic positions though the bulkhead or in the top of the host pipe, depending on the site conditions. A minimum of one vent port, in addition to the grout injection ports, is recommended, unless the grout is inserted into the annular space through a hole large enough to serve as both. Vent ports also serve as grout verification points and preparations must be made to adequately close off the opening once grout Vent ports are generally four feet in length to extend just beyond the bulkhead. 'P WWW.CULVERT-REHAB.COM 1 (800) CULVERT 43 i► 144 L----- J begins to flow out of the area. A vent port placed at the bottom of the bulkhead will help drain water that may be in the culvert system. The purpose of the bulkhead is to retain the grout within the annular space until hydration occurs and the grout material hardens. Many different materials can be used to accomplish this task, such as a low -slump concrete mix, a stiff grout mix, wood, soil, etc. The conditions at the site, the type of grout selected, and what substances are available at the time will dictate what bulkhead material is best for an application. Grout should be placed into the annular space patiently. The material must be given time to flow along the pipeline and run out though any holes that may be in the host pipe, or through separated joints in the line. When possible, gravity should be used to place grout into the annular space. A low density or cellular grout material will flow along the space exiting out through gaps in the host pipe and replace lost bedding soil around the host pipe. Once the voids are filled, the grout will continue to flow down the pipe length and slowly fill the annular space between the liner and host pipe. Patience is critical with the grouting operation. Grout pumping may be necessary in some applications. The pump pressure is used to move the grout from the mixing tank, through the injection port, into the annular space. For long culverts, extended sections of PVC pipe can be used to place the grout further into the culvert to efficiently fill the space. At the point where the grout exits the PVC pipe, the pressure quickly dissipates to zero. If a back pressure is noted by the pump operator, the pumping should be stopped. Many pump truck pressure gauges don't have the sensitivity to perceive a low pressure (2 psi). Exerting unnecessary pressure within the annular space, on the outside of the culvert liner, can cause unwanted problems, from grout leaking through the joints to a catastrophic collapse of the liner pipe. Although this occurrence is rare, patience and common sense should be used during the grout injection operation. Periodically look WWW.CULVERT-REHAB.COM I (800) CULVERT inside the Snap-Tite'g' liner pipe to assure these events are not occurring. Grout Verification As mentioned in the preparation section, grout verification ports can be placed to monitor the grouting operation. Short pieces of PVC pipe can be placed through the bulkheads to serve as vent ports for escaping air in the system and grout verification ports. When grout begins to flow from these lines, a cap can be placed over the pipe to stop the flow. A threaded section of PVC, with a threaded cap, is recommended to accomplish this task. Quality Control & Testing The primary grout measurement to obtain is the unit weight (ASTM C138) of the mix prior to insertion into the annular space or the slip lined culvert. The materials required are a calibrated unit weight bucket, a tool to strike off or level the surface, and a scale. The density (unit weight) of the material has a greater effect on the performance of the culvert rehabilitation that the compressive strength value of the grout. Practically any grout selected will be stronger than the Grout can be seen existing from the PVC port Jaynes W. Fowler Co. VMFn Ccneril (;i,nUact�>rs 8.1 3 2 Au,9 er• Bo4 ;,:COkJ 42.11-JI�C. Submittae Transmittal d i'h �r 8 � a� Z I-t+► Submittal No. S005 Date: 08/11 /2011 Lake Ave S/Rainier Ave S Storm System Project To: Daniel Carey From: Shannon Phipps Co.: City of Renton Co.: James W. Fowler Co. WE ARE SENDING: ❑ Attached ❑ Enclosed ❑ Under Separate Cover Via: THE FOLLOWING ITEMS: ❑ Submittals ❑ Product/Data ❑ Samples ❑ Plans ❑ Shop Drawings ❑ Copies ❑ Specifications ❑ Contract ❑ Other: TRANSMITTED AS CHECKED BELOW: ® For Approval ❑ For Review and Comment ❑ For Your Use ❑ Per Your Request ❑ Other: Copies Spec Section Description of Product / Data Subcontractor / Supplier 1 7-20.2 S005 - BI 32 Auger boring 42in Steel casing James W. Fowler Co. Contact: Pa�a M r, �-lx 04 v-,,e,,, JamesW r,)%,&r(:o- Submittal Transmittal I Submittal No. S005 0 r, A, 1fF,1 Geiierail 0mitracturs Date: 08/11/2011 Lake Ave S/Rainier Ave S Storm System Project To: , Daniel Carey From: Shannon Phipps ------------ 1 Co.: I City of Renton James W. Fowler Co. WE ARE SENDING: Z Attached El Enclosed ❑ Under Separate Cover Via: THE FOLLMMING ITEMS: Z Submittals [] ProducUData 0 Samples 0 Plans n Shop Drawings 0 Copies [] Specifications [] Contract F1 Other: TRANSMITTED AS CHECKED BELOW - [I For Approval Z For Review and Comment E] For Your Use E) Per Your Request D Other. Copies Spec Section Description of Product! Data Subcontractor/ Supplier 7-20.2 S005 - BI 32 Auger boring 42in Steel casing James W. Fowler Co - REMARKS: %4 NO FYCEPTION TAKEN 1W rOTZP..ECT10*,4S N!CTED U, REJECTED )U REVISE AND RESUBMIT El SUBMIT SPECIFIED ITEM [3 SEE ATTAMED COMMENT SKET DATED CP1CMNG IS ONLY TOR GENERAL CORr-OFMAICE WTH THE DES'G M 0t1- C T Of THE PROJECT AND GENERAL CWTUANCE'Wri H TTIE 14FOpMAT04 C IN THE CO'JPArT DaCUMENTS, ANY ACTION SMOV1174 13 SU15,1ECT TO THE RMAR111i' 11TS OF TAE PLMS AND SPECRCATIGNS. CONTZA�,.T'iR IS RM"IMICLEFOR: DUMS AM WIHICHSIiAM BE C01117,10ED AND CORF CIL- AMATTHEJOSS17F; FABRICATIO14PRO"t-SSE3ANBTECI?1,<IQUESOFCON- A S 74,UCr*N, COU"REINA.TION OF HIS WORK VIT H THAT OF ALL OTHER TRADES AND THE SAMPACTORY PERFORMANCE OF WORR& D A T E ZI BY BI-32 n+el W Carey 4 21 C.'sI'>r N L 8 -0- 11 From: Sent: To: Cc: Subject: Attachments Daniel, For your review. Thank you, Shannon Phipps Project Manager Phipps, Shannon [shannonp@jwfowler.com] To PMX Thursday, August 11, 2011 2:45 PM Daniel W Carey Nolen, LaRue JWF S005 - BI 32 Auger Boring 42in Steel casing PermaLok casing piping.pdf; JWF S005 BI 32 Auger Boring 42in Steel casing.doc James W. Fowler Company PO Box 489 Dallas, OR 97338 Office: 360-355-9045 Mobile: 360-239-7320 D n ly PERMALOK The Interlocking Pipe Joining System TO: James W. Fowler. Inc. P.O. Box 489 Dallas, OR 97338 DATE: Auzust 11, 2011 CUSTOMER JOB#: PERMALOK #: S00309 LOCATION: Renton. WA ATTN: Shannon Phipps We X enclose herewith the following drawing (s): Sheet Nos. Submittal No. of copies Original and one copy Prepared by Permalok Corporation Showing 42" OD Permalok Steel Casing Pipe For: Approval orrec ion or resubmission Distribution Use/Record or file Approved - proceed with work Approved as noted - proceed with work REMARKS: Please call me as soon as you receive approval of this submittal or if you have anv auestions. Regards, Gary W. Huber Senior Sales Representative Permalok Corporation • 472 Paul Avenue • PO Box 10970 • St. Louis, MO 63135 314-524-1900 • 800-280-5511 • Fax 314-524-5702 • www.permalok.com PERMALOK The Interlocking Pipe Joining System CERTIFICATION Date: August 11, 2011 Sold to: James W. Fowler, Inc. P.O. Box 489 Dallas, OR 97338 Attn: Shannon Phipps RE: . City of Renton, WA Project # 27-3529 This is to certify that the 430 linear feet of 42"OD x .625" wall (276#/ft) new DSAW rolled and welded steel pipe furnished on the above referenced project meets Permalok Standard Specifications (no hydro) and is of domestic manufacture. All materials in Permalok Connectors, in addition to the above, meet or exceed the requirements of ASTM A-36. Permalok -orporation ary / . Huber Re: SN S00309 Permalok Corporation- 472 Paul Avenue • PO Box 10970 • St. Louis, MO 63135 314-524-1900 •800-280-5511 • Fax 314-524-5702 • www.permalok.com PERMALOK The Interlocking Pipe Joining System STANDARD SPECIFICATION FOR PERMALOK STEEL CASING PIPE SCOPE: This specification is intended for steel pipe utilizing an integral press -fit connection method proprietary to Permalok Corporation of St. Louis, MO, for use as encasement pipe for carrier lines of water, sewer, gas or other products. Permalok steel pipe for use as the actual product carrier is covered by a separate specification and not included here. PART 1 MATERIAL 1.1 All steel used in the manufacture of Permalok steel pipe shall conform to the requirements of ASTM A-36, ASTM A515, grade 60 or ASTM A572, grade 42. 1.2 Steel used in the manufacture of Permalok connections shall conform to ASTM A-36 as a minimum and be machinable. PART 2 DIMENSIONAL TOLERANCES 2.1 ROUNDNESS The pipe diameter as measured along any single plane shall not vary more than 1 % from the specified diameter. 2.2 CIRCUMFERENCE The outside circumference shall not vary more than +1% from the nominal' circumference based on the specified diameter, or ± 3%" maximum. 2.3 WALL THICKNESS The actual wall thickness of the steel pipe sections shall not vary more than 5% under the nominal wall thickness specified. 2.4 STRAIGHTNESS The maximum straightness deviation in any 10' length shall be 1/8". The maximum straightness deviation in fabricated sections up to 40' shall be 3/8". Page 1 of 2 PART 3 MANUFACTURING 3.1 Permalok steel pipe 24" and under shall be either ERW or seamless at the option of the manufacturer. 3.2 Permalok steel pipe 30" in diameter and over shall be manufactured by the rolled and welded cylinder method utilizing the DSAW process in sections of not less than 8' long, except as needed to achieve the final finished length of pipe. 3.3 Permalok connectors shall be full penetration butt -welded square to the ends of pipe sections, or profiled directly on the finished sections, at the option of the manufacturer. 3.4 Spiral welded pipe will be permitted only at the request and/or approval of the purchaser. PART 4 QUALITY CONTROL 4.1 All welding shall be performed by qualified welding operators in accordance with the requirements of ANSI/AWS D1.1. 4.2 All welding procedures shall be either pre -qualified in accordance with ANSI/AWS D 1.1 for full penetration welds, or qualified by testing, as required. 4.3 One reduced section tension test specimen shall be evaluated for each lot of 1000' of each size and wall thickness, and shall show a tensile strength of not less than 95% of the minimum strength specified for the grade of steel used, unless waived by the purchaser. 4.4 Hydrostatic testing is not required. 4.5 All Permalok connections shall be examined at time of shipment and shall be free of injurious defects or that section shall be rejected and repaired prior to shipping. 4.6 All Permalok pipe shall be clearly marked with the manufacturer's. name, manufacturer's job number, customer name, OD, wall thickness, and weight per foot. Page 2 of 2 Permalok - The Interlocking Pipe Joining System Page 1 of 1 A. -PERMALC)K Tile hltarlockinp PipD.JOiuinp Sysl:urn ��. tR4.r.n1FN9i'!a: �I* 7echnical > T5 Pipe Joining Profile a, Department of Civil a6 �Pn'aiL A. David A. Pecknold r 'a Engineering Rami M, HaJall Unlverslly of Illinois September 1995 at Urbane-Chanpaign _ I _ d, Structural Analysis of flea Permnlolc 31np1 Plpu JDining Syaiarn for 10-inch. 36-Inch and 60-Inch diamelur eteel { 1 pipe �iPeSri1� B�P�[I�I.AIl�lY.S1�.1t§-�o" Loading Conditions r`4'P s y M, WINO?�f �4 (R12 ' 4,:. 'uiS1( t .�; fi .:' /"1� `r�(i � i 5 S,.c• • �- i. ; �' tM �:. 1 �koslnp .the Joint Com.prmsslan 'TarLsion Compression/Tendon Table 10-Inch ID 36 - Inch OD 60 - Inch OD 0.375 - WT 0.5 -Inch WT 0.75 - inch WT Loading Cand. Axial Force (kips) Axial Stress (ksl) ort/a�' Axial Force (kips) Axial Stress (ksi) c o ✓) •Axial Force (kips) Axial Stress (kal) -"/ '. Closure 32 2.62 0,073 1 21 0.38 0.011 68 0.49 0.014 Comp. 440 36 1.o 1967 35.3 o•98 5025 36 1.0 Tension I 257 21 I 0.58 1 956 17 0.48 1675 12 0.33 II j�r'�j'��;rf�b�'J�j1�i•,�p•`I�'Nf�1 � nentiing T'nblo Loading een�psMl)m.2 Axial2 Force M/M,3 Band.M m. Forlce Bend, Mom. •M/Mr,3 Axial Fe M/Mx3 (ksl) (ksl) s (psi) (ksl) InL Press, I 2650 35.3 0,90 1012 35.4 0.98 910 35.5 0.99 3 Hoop stress aG = 1D,12t, wherop c internal pressure, 1), = Inside diameter, and i = wall thickness 2 Limiting (maximum) bending moment 3 The plastic momentAl11Js cslculotad from A/,,-Y / D.'- D,'I Q)• where Dr Is the pipe ID, D„ Is the pipe OD, and ay Is the yield stress (36 ksl), Permalok - The Interlocking Pipe Joining System Page 1 of 2 PERKM 1. The'FnterhGakin PIpa 6iwiI Systl m Technical > T7 Analysis 1 > T5 Analysis 2 > T7 Analysis 3 PERMALOK CORPORATION 472 Paul Avenue St. Louis, MO 63135 au Attention: Dave Mittler Report of Analysis October 22, 2002 Lab No. 02P-1946 SAMPLE ID: #5-30" Permalok Connector Joining System SUBJECT: Hydrostatic Pressure Testing TESTING SITE: B & D Metals Products, 5980 St. Louis Avenue PROCEDURE: Testing blinds were attached to a shortened length of the connector assembly and placed into the test fixtui Prior to assembly and installation both male and female couplings were visually examined for proper tol.erai joint type and fit up. The coupling halves were then pressed together using the necessary jacks, shims and clamping fixtures. Figure 1 illustrates the typical set up and configuration of the fitted 30" Permalok Conner The sealed unit was then hydrostatic pressure tested with potable water to a pressure of 90 psi and held fo minutes. The pressure was then increased to 150 psi and held for an additional 15 minutes. RESULTS: No deformation or drop in pressure was noted during the testing of the above identified connector assembl KS/kss Karl Schmitz, Director Materials Testing St. Louis Testing Laboratories, Inc 2810 Clark Avenue St. Louis, MO htto://Dermalok.com/t5 test2.html 8/11/2011 I [a N Cd w k G" 0 0 N r-, C6 N U N Cd U t-a M m I "tI vn _ L o I a I ra❑. I co i N m m = b Q1 J G z O � Q 3 7 J O M i > w c Q W w' 4 o =UJ W\ aoo `WCl � n.a N ¢ . m ❑ asa 6 A C C � h W o a cn U) 1 Z Ln I O I W I p > Q I 1 � •� u � c 1 O a� CCS a DO W 1 , I 1 1 I I I I I 1 1 I 1 I 1 I I I I , I I 1 1 1 , I I I , I 1 1 I 1 I I 1 I I I I I I I y y C c�i I I 1 1 , I I 1 1 1 I I I 1 I I 1 I I I I I I I I I I I 1 I I , I I 1 I s '3 b � , I I I , I I = ' � cV f I I 1 1 I I I I 1 1 I I I t I I I I I 1 , I I 1 I I I - I -- I i , , 1 I , I 1 I I 1 I , I , , , I , I I , I I , , - - - -- o d o 0 Cf) cc CL W e < <n U) >" Z m Q E WCil A o N zz � N o w C) G UD = 1 n n � o os N U U (1) bID v©©o© . w � a U � a N w 0 2 H 7 c � W o x U OR F x iV fV N 1 1 1 1 1 I I I I 1 I I I I I I 1 1 I I I 1 1 1 1 I I 1 1 ' I I' I 1 I ! 1 I 1 1 I 1 I I I I 1 I I I I 1 I I I 1 1 1 ' I ' I I I I I 1 1 I I I ! I I 1 I o �6� z o S H � 'N S O=� m Q C m ❑ Y O OLU as Qaw w ❑ a � N m L � } W m Y U rn 1- Z C [� ELI C] Q = .. C, N z° FBI CO C cn0 b air Oo 4 O to O C 0 -0 N U y cyd o .0o *' A N ► ti W rl� r� m I ,t I v, N fV A O N � O N to :t m \ LJJ c A A. 9Z9' W kn O E-+ N N O x O O N, O N I m I t I � 9Z9' O � N Q V/ Z _ �o`� N g o N CL a p 'J x oho a Ex o w=� � m a' yaQ H A A°w fA w Z O H (� Q � Ca W z N ri V v, I � T o m a N ' SZ9' � rn c ODN N 2 o o U in o m O Y- O d � � O N Q N n�i c C N m tt- g Q Ae U O (n � Z O Cn H % A W a Ln O H kn VIC N O k O O N O w /6 a a U b �1 � d � 2os ¢ o 'O N A ai m � K ❑ Q. 2 ONO U x O as "a F- C � Cf ~ ~ W m QQ U U M�M W z o � > Q PERMALOK The Interlocking Pipe Joining System Preparation Checklist Permalok steel pipe is manufactured with precision machined surfaces on each end. Damage to these surfaces can make the product unusable. All construction personnel involved in the handling and installation of Permalok steel pipe should be thoroughly instructed in the proper methods of unloading, storage and jobsite care of this product. I. Handling and Unloading 1.) Upon arrival at the jobsite, and prior to unloading, visually inspect each piece of Permalok pipe for any damage to the ends or body of the pipe. Any possible damage should be noted on the carrier's bill of lading, signed and dated, and the damaged pieces marked and segregated from the rest of the shipment. Immediately advise a Permalok representative of any product damage, so replacement pipe can be expedited. 2.) One of the first shipments to the jobsite should have the lead section of Permalok pipe, the push ring, and RTV silicone sealant and additional copies of the checklist. If these items are not received, contact your Permalok representative. 3.) Never unload or move Permalok pipe by the use of hooks in the pipe ends. Fork lifts, chain cinches, or wrap around straps are preferred. Permalok can provide pipe with lifting eyes/lugs attached upon request. 4.) Permalok pipe should be stored off the ground on suitable supports (4 x 4's, sand bags, etc.) to minimize damage and rust from the ground contact. If pipe is to be stored at the jobsite for an extended period prior to use, care should be taken to prevent rust from forming on the machined surfaces. 5.)_Internal bracing should be left in place until after the pipe joint is mated, if possible. If bracing needs to be removed for insertion of auger flights, care should be exercised to prevent augers from damaging pipe ends when inserted. 6.) In the case of Permalok pipe ordered with coatings and linings, any transit damage should be noted on the carrier's bill of lading. Repair kits for most coatings and linings are available for field repairs from your Permalok representative, upon request. H. Launch Shaft or Pit Preparation 1.) Installation crews should be completely briefed in the proper care and handling of Permalok pipe. Permalok Corporation • 472 Paul Avenue • St. Louis, MO 63135 • P.O. Box 10970 • St. Louis, MO 63135 1-314-524-1900 • 1-800-280-5511 • Fax: 1-314-524-5702 • www.pertnalok.com 7/15/05 2.) Adequate jacking force from your trenchless equipment is necessary to make up the joints on Permalok pipe. Most trenchless installation methods provide more than enough compressive force to mate the joints properly. If there are any questions, contact your Permalok representative for assistance. 3.) The first section of Permalok pipe must be properly restrained against forward movement to ensure that the joining process with the next pipe section can be done successfully. It is recommended that restraint be applied on several of the succeeding connections until ground force resistance is enough to allow the joints to mate properly. Contact your Permalok representative for suggestions. 4.) When planning your launch shaft, be sure to take into account that the Permalok push ring will add 3" to 4" to the length of the pipe sections. If your installation method is pipe ramming, the reinforced push ring will have an additional 12"added to it. III. End Preparation, Mating Procedures, and Installation 1.) Both ends (male and female) are coated at the factory with a wax -like rust inhibitor. This must be removed before attempting to make up the joints. Use of any type of petroleum based solvent and a stiff brush will dissolve the film, which can then be wiped clean with a rag to leave a bright, clean shine. 2.) Just prior to initiating the mating procedure, a bead of RTV silicone sealant should be applied to the machined surfaces of the male and female ends. This provides a temporary lubricant to ease mating the joints and, additionally, will cure in 5 to 10 minutes to form a sealant barrier. It is not necessary to wait for the sealant to setup after the joint is mated, just proceed as normal with the jacking operation. Do not skip this step of using the RTV. 3.) A push ring is provided with your pipe order. This ring fits firmly into the female end of the Permalok pipe to protect the end from damage during joint make up and jacking. Do not attempt to advance the pipe without use of the push ring. 4.) Permalok pipe is flexible and the joints are a precision machined fit. When starting the initial mating procedure, the joint should be stabbed from top to bottom, or bottom to top, not straight on, until the leading edge of the male joint is completely engaged in the female end (see illustration). As steel pipe is never perfectly round, it is good practice to measure across the face of each male and female end to determine the maximum and minimum deviations from round, prior to placing the pipe for joint make-up. Match marking the pieces in this manner will aid and speed up the mating process in the work pit. Illustration for stabbing Permalok joint Just get it started push female male ring female male Ili push ring 2. Then let your jacking frame do the work. Permalok Corporation • 472 Paul Avenue • St. Louis, MO 63135 • P.O. Box 10970 • St. Louis, MO 63135 1-314-524-1900 • 1-800-280-5511 • Fax: 1-314-524-5702 • www.permalok.com 7/15/05 5.) Once the joint is pushed completely home, check the circumference for any noticeable gaps in closure. Most of the silicone will squeeze out of the joint upon closure. It is not necessary to clean this off of the pipe. IV. Special Applications 1.) If using the Permalok Type 7 (gasketed) joint, make certain that both gaskets are completely seated in the bottom of the groove. Care must be taken to avoid cutting or misalignment of the gaskets. 2.) When using the Permalok HDD connection, it is not necessary to stab the joint as above. This joint is designed to make up in a straight line fashion, to facilitate the use of your HDD equipment. 3.) When pipe ramming, several additional considerations need to be addressed. In order for the hammer energy to be fully transmitted, all connections between the push ring and casing and the hammer and push ring need to be secured tightly, with chain and strap rigging. It is also recommended that once the joint is stabbed, it too is tightly secured prior to starting the hammer to close the joint. This is to prevent any rebound effect that might make it difficult to close the joint. It is recommended that you contact the hammer manufacturer and your Permalok representative for suggestions prior to starting a ramming operation. 4.) It is possible to use Permalok pipe in an open cut installation. For advice on field methods for making the connection, contact your Permalok representative. If for any reason you experience any difficulties in the handling or installation of Permalok pipe, please contact a Permalok representative immediately for assistance at 800-280-5511. Permalok Corporation • 472 Paul Avenue • St. Louis, MO 63135 • P.O. Box 10970 • St. Louis, MO 63135 1-314-524-1900 • 1-800-280-5511 • Fax: 1-314-524-5702 • www.permalok.com 7/15/05 2 Avg et- t3ori n_9 Mae I;h e. A p to d, Jwws W. Fowl,,-r G), Submittal Transmittal �, �,�� Submittal No. S015.1 Date: 09/20/2011 Lake Ave S/Rainier Ave S Storm System Project To: Daniel Carey 1 From: Shannon Phipps Co.: City of Renton Co.: James W. Fowler Co. WE ARE SENDING El,,.*tEcked EJ Enc osed F-I Under Separate Carer Via. - THE FOLLOWING ITEMS El Sitmittals ProducMiata E] Samples ❑ Plars ❑ Shop Drawings ❑ Copies El Sclecifications. R Ccnkract [I Other: TRANSMITTEDAS CHECKED BELOW GI For.Approvai E,7:For Review and Comment E]ForYou-Use F Per Your Request ❑ other - Copies Spec Section Description of Product Data Subcontractor! Supplier 1 7.20.3(5) SO' 5.1 - 6132 Auger Bcring k4a&ine James '%,V, Fowler Co ----- - - - - ------- -- .......... ---- ------- REMARKS, PARAMETRIX Fo m 61-CN-Pifty, 54;nCS SHOP DRAWING TRANSMITTAL To: Pararretrix, Inc. Transrnittai No.: S015.1 Address 1019 39" h Avenue SE, Suite 100, Puyallup, WA 983714 Attn: Chuck Schott Date:-—�� Project: Lake Ave Storm System Project No.: 2.18-1779-036 Owner, City of Renton - Daniel Carey Lccaton_ Rerton Previous Transmittal No. (if resubmitted) USE ONE FORM PER ITEM SUBMITTED Spec. Paragraph Number Spec. Page No Item Descr tion and Use Manufacturer Dwg_ No(s). Approval Status (Engineer) 1 7-20.3\15) Auger Boring Machine James W Fowler Co. By this submittal, the Contractor represents that he has determined and verified all field rneasLrements, field conslnic:ion criteria materials. catalog numbers and similar data, or will do so, and that he has checked and coordinated each Shop Drawing Voth the project requirements and the Contract Documents. Deviations from ti-e Contract Documents are noted below. COMMENTS: Con :tractor To, James VV Fo%-Aer Co 127751Nestvierr Drive Dallas, CEt9gr 97338 Signature (THIS SPACE FOR ENGINEER) Cate -D-I! Enclosed are copies of the above item. Approval status as noted above is in accordance voth the following legend: A. No Exceptions Taken Make Corrections Noted C. Rewise and Resubmit D. Submit Specified Item C, Rejected F. See attacl'ed Review Commert Sheet dated PARAMETRtX, 'NC. CC' File Jai ties W Fi viler Co. W 41 ® " Ccncra_1 �. f)I It 1'..k t,(>r'ti JWF S015.1 BI 32 Submittal 7-20.3(5) Auger Boring CITY OF RENTON LAKE AVENUE S / RAINIER AVENUE S STORM SYSTEM PROJECT James W. Fowler Company 12775 Westview Drive Dallas, Oregon 97338 503-623-5373 11UT ANINIKIR Lake Avenue S. Storm System Project, Renton, WA. — JWF SO15 - BI 32 Auger Boring Machine -1- Auger Boring Work Plan Qualifications • Microtunneling, auger boring, pipe ramming, carrier pipe installation, sand fill and grouting expertise, in addition to a fleet of trenchless equipment makes James W. Fowler Co. uniquely qualified to perform a variety of challenging trenchless projects. With a reputation for successful completion of a variety of complicated projects across the United States, our tunneling division is quickly becoming recognized as a leader in the industry. James W. Fowler Co. Pipe Ramming & Auger Bore Experience Pipe Project Name Owner Ram / Length Diameter Carrier Casing Auger Pipe Bore Anacortes Waterline Replacement City of Anacortes AB 140' 36" Ductile Steel 360-293-1920 Iron Anacortes Waterline Replacement City of Anacortes AB 310' 36" Ductile Steel Iron Anacortes Waterline Replacement City of Anacortes AB 405' 36" Ductile Steel Iron Central Oregon Irrigation Ductile Pilot Butte Canal Pipeline District AB 100' 48" Steel 541-548-6047 Iron Three Mile Lane Trunk Sewer Replacement & City of McMinnville, OR AB 100' 30" Steel PS 503-434-7312 Woods Street City of Portland AB 140' 54" Steel 503-823-8972 Qualified People LaRue Nolen- Superintendent and Bore machine operator Todd Nolen — Bore machine operator Sharyn Hopson — Safety Manager 1. Auger Boring Equipment and Installation • A Barbco 48/750 will be used to auger and jack the 42" casing. See attachment A. After the pit is excavated, the sub grade will be examined to determine if the sub grade is firm and unyielding. The focit print will be over excavated to place 5/8" crushed rock. (The crushed rock is installed for ease of leveling the surface to final grade.) The crushed rock will then be carefully graded for slope, elevation and alignment. This will be checked against the survey stakes. We will then place steel sheets on top of the crushed rock. Past experience with similar distance, size and soil type's gravel and steel sheets are more than adequate for this type of auger bore. If we do find the ground to be soft and yielding we will have to over excavate and pour a slab to place the steel sheets, rails and machine on. Lake Avenue S. Storm System Project, Renton, WA. — JWF SO15 - BI 32 Auger Boring Machine -2- Again, the steel sheets will be checked for elevation, slope and alignment. On top of the steel sheets, the steel rails will be placed and checked for grade, elevation and alignment. • If necessary, the steel rails can be fine tuned using steel shims. During auger bore operations, the rails and pipe will be checked for grade slope and alignment. • The spoils will be removed by using a Barbco 42-11VIHD auger. Product data attached (see attachment B) While auger boring and pipe jacking, the auger will be removing the soil inside the 42" pipe. As the auger extracts the spoils it will be extruded to the side of the auger. From there the spoils will loaded with an excavator to the adjacent roll off bens or directly into trucks. • The casing pipe and joints will be Permalok bell and spigot and have been provided under a separate submittal. • Cutting head are fabricated in house and have similar components to these. • I I'll) Cutting head The HTD Cutting Head by American Augers is a versatile -field proven cutting head that is equipped with carbide cutting tips to handle dirt, soft rock, clay, sand, and other intrusive low impact ground materials. Select Required Hex Size to Retrieve Product Information Table Hex Size 5 Wins; Cutter Wing Cutters by American Augers are the essential cutting head accessory especially when the job requires the need to enlarge the bore for easy installation of product casing. Wing Cutters are designed to fold in when the auger is operated in reverse. After the Barbco 48/750 is placed on leveled and aligned pipe rails, the first length of 42" pipe will be advanced to the face of the excavation. The pipe slope, grade and alignment will be rechecked. The pipe is secured to the master casing pusher and has a push ring to protect the bell end of the Permalok casing. The boring begins, and the pipe is advanced until just enough pipe remains outside the excavation. The ram is suspended, and the second piece of casing is installed to the first. The pipe is re -secured and the process is repeated until all the pipes are installed. The auger boring which consist of the cutting head, auger and jacking will happen simultaneously. The elevation will continually be checked with the water grade indicator (see barbco pg 38-43) and adjustments can be Lake Avenue S. Storm System Project, Renton, WA. — JWF SO15 - BI 32 Auger Boring Machine -3- made using the steering road. The alignment will be checked at the start of the bore and every 60' with the use of a pipe laser. This will require the augers and cutting head to be removed and the pipe laser aligned in the pit with the marks transferred from the survey off sets established in the parking lot. We will be using a Topcon TPL 4GV pipe laser or similar. Product info attached. We can shim the augers at the head to adjust the casing right or left as needed. 2. Jacking System Details • Maximum jacking force is 874,628 Lb. • This unit has 3) 8 inch jacks with a stroke of 36 inch located at the bottom of the unit. (see pg 20) • Thrust block configuration is shown on shoring design. It is made up of a steel sheet placed behind the Barbco push bar and the shoring. The steel sheet is aligned with the push bar of the Barbco and gravel is placed behind it and the shoring to make for a solid thrust block. 3. Provide estimated Jacking force for Auger boring drive. • Auger bore #1 208' - 217 kips • Auger bore #2 74' — 70 kips • Auger bore #3 150' —153 kips 4. Casing pipe calculations • See attached calculations from BRA. 26.5 ksi 5. Installation of line and grade. • A line transfer unit LT8-300-LTU and grade level will be used to transfer line and grade from offset established by the surveyor to the pit floor. • See Manufacture's literature describing the casing installation Attachment A. • The elevation will be checked continually with the use of the water grade indicator and the alignment will be checked every 60' with a pipe laser. 6. Schedule • See CPM Schedule 7. Steering system • Steering system will be assembled using a steering knuckle to control the elevation / grade of the bore simply by turning the head up and down with the steering rod. To steer the system for right and left will install shim plates at the leading augers inside the first casing piece to position the head in the correct location while augering. Since the head rotates counter clockwise while facing it from the front the tendency will want the bore to turn left. We carefully shim it slightly right to compensate and make adjustments as needed. 8. Main Jacks, thrust ring, jacking controls, and pressure gauges. • See attachment A. Lake Avenue S. Storm System Project, Renton, WA. — JWF SO15 - BI 32 Auger Boring Machine -4- • A method. Most commonly used when boring formations. Using the electric thrust joystick in conjunction with the thrust speed dial and thrust limiter simultaneously gives the operator infinite control of the forward advancement speed and force applied to the cutting face. While using the tall toggle switch to control the engagement and disengagement of the clutch. Iu D. THRUST rf !1 1 iG11' 1 �1 �uWBG Esmp ®.. C' O- @ Doc � wwa oonr • This will be a steel sheet that is placed between the back of the machine and the shoring. The steel sheet will be squared up to the rails and gravel will be place between the jacking sheet and the shoring making it a solid thrust block. 10. Pipe Lubrication injecting system. • See attachment D for the product and equipment. 11. Excavated Spoil handling. • The spoils will be removed by using a Barbco 42-11VIHD auger. Product data attached (see attachment B) While auger boring and pipe jacking, the auger will be removing the soil inside the 42" pipe. As the auger extracts the spoils it will be extruded to the side of the auger. From there the spoils will loaded with an excavator to the adjacent roll off bens or directly into trucks. • Soils samples will be checked by the mobile lab and monitored with a PID detector. Workers will be following the HASP previously submitted. Lake Avenue S. Storm System Project, Renton, WA. — JWF SO15 - BI 32 Auger Boring Machine -5- 12. Survey. • W.E. Coats surveying surveyed the offsets for the Centerline of the bore and CB's. • We will run the remaining control off of these offset marks. 13. Safety Plan. • Hoisting pipe into launch pit -See hoisting & lifting in (SSSP) Site Specific Safety Plan. • Welding -Welding and Hot Work will be performed. A fire extinguisher will be near welding area. Any potential flammable materials will be removed from the immediate vicinity. PPE' will be worn per the SSSP. • Shoring — The launch pit will be shored with an Efficiency brand Trench shields and plates, Certification and design approved by an Engineer will be submitted in a separate submittal. • Addressing obstructions -If a subsurface obstruction is encountered, work will immediately stop. The Project Manager for the City of Renton will be notified. If the obstruction needs to be removed, the pipe will be augered clean. The pipe is a confined space, and a confined space entry permit will be required. We will follow the confined space procedures in the SSSP & HASP. • Dewatering- We will be installing well points on approximately 10'0" centers along pipe alignment and bore pits. See Dewatering submittal. 14. HDPE pipe. • Submitted as a separate submittal. 15. Casing spacers. • These will be T-0" long pressure treated located at 8'-0" centers approximately 2" x 4" laying horizontal on the pipe. Stainless steel bands and spacing will be per detail 2 on C-6. • After casing pipe is installed the pipe laser will be set up and measurements will be taken at 8'-0"centers that correspond to the carrier pipe. The casing spacers will be trimmed accordingly. 16. Contingency Plans • If an obstruction prevents the 42" casing from advancing, the following plan will be implemented: • Use auger to remove spoils, so leading edge of pipe can be exposed to determine the type of obstruction. Lake Avenue S. Storm System Project, Renton, WA. — JWF SO15 - BI 32 Auger Boring Machine -6- • Prior to entry, all procedures of the confined space entry plan, SSSP, and HASP will be in effect. • Workers will enter the casing to expose and determine the type of obstruction. • If the obstruction is a rock or boulder, jack hammers and chipping guns will be used to break apart the obstruction. • If the obstruction is wood, electric chain saws or reciprocating saws and other similar devices will be used to break apart the debris. Lake Avenue S. Storm System Project, Renton, WA. — JWF SO15 - BI 32 Auger Boring Machine -7- Sheet Cw of Project fzenEmv, 1 1e j Knt-1 - SkVr", Sg �4-E� E3RA Subject �- �,, ✓§ Fc�-cep Job Number tn Computed By mVk/ Date n--17 _11 Checked By JACKING FORCE CALCULATIONS RENTON STORM SYSTEM LAKE/RAINIER AYES RENTON, WASHINGTON Prepared for: P, -4g9 4RAT F 8 Sheet t of Project E 3 RA Subject 1,4 Job Number F- I i O5pl Computed By -GA4 Date 9.4'7-1/ Checked By 42,6 F3.(ee( cQs�e,2n obov�q di 0"0 e So 1,b ia!5 �rt a 4b/2._ I�f 9 A- pco-/- 6.01 loipx-- t--s i(o, �,50-5 'ATq:`- F�Dr-- c2p :1 a (e-)5 ,-7- C., rvP R (e) '15 ktfl!l Tl— 4Z4, O,bZs'\ '5 OAIOOI;44-L�/-3 I\I1CV'l:4W' ro 9 ^Sheet iof Project ia�Fx: �l/-12e��o� 'f a��/ 1c41✓iF� RJR e fN E3RA Subject :Jnc!gnn Job Number ,_ (( Computed By DNLW Date 9 -11 - 0 Checked By eec +uea(ctpplrccvttrj�i , bonaV,g G-c6--, uid ( be i,edoc.,�-c vs►�9 Fo-r bevy p of l r v-CT /ves CP F rc i-o,A %x-ce a^ F Fe- (e<f- -k'v\ !' cam �o 4,, 4-' 10F( �n - fiL p telll) f� S,o,( ;DtI t le� G W e CIS C96,--t UL . +,k e- 4U— --74 pt e (" h ,. r c r ' `70 k,ps io BORE -GEL" Description BORE -GEL® single sack, boring fluid system is specially formulated for use in horizontal directional drilling (HDD) applications. BORE -GEL fluid system is a proprietary blended product using high -quality Wyoming sodium bentonite. When BORE -GEL system is mixed with fresh water, it develops an easy -to -pump slurry with desirable fluid properties for HDD. Applications/Function Provide optimum gel strength with minimum viscosity for cuttings suspension and transport • Improve borehole stability in poorly consolidated/cemented sands and gravel formations • Reduce filtration by forming a thin filter cake with low permeability • Lubricate pipe in microtunneling operations • Produce a pumpable slurry with maximum amount of reactive solids for borehole stability Advantages Minimizes the number of boring fluid products required • Easy to mix and fast to yield • Low viscosity minimizes pump pressures • Provides lubricity for pulling product line • NSF/ANSI Standard 60 certified • Can be used in Water Wells in unconsolidated formations or when additional gel strengths are required to compensate for low annular velocity Typical Properties Appearance Tan to gray powder pH (4% slurry or 15 Ib/bbl) 10.2 Bulk density, Ib/ft3 68 to 72 (compacted) © Copyright 2008 Haffiburton Rev. 512008 • IDP 032 BORE -GEL Is a registered trademark of Halfiburton Because the conditions of use of this product are beyond the seller's control, the product Is sold without warranty either express or implied and upon condition that purchaser make its own test to determine the suilability, for purchaser's application. Purchaser assumes all risk of use and handling of this product. This product will be replaced if defective in manufacture or packaging or if damaged. Except for such replacement, seller is not liable for any damages caused by this product or its use. The statements and recommendations made herein are believed to be accurate. No guarantee of their accuracy is made, however. 11 5h4- 4 OFF Recommended Add slowly and uniformly through a high -shear, jet -type mixer over one or Treatment more cycles of the volume of slurry. Continue to circulate and agitate the slurry until all unyielded bentonite is dispersed. Recommended application amounts Boring Application Ib/100 gal kg/m3 Normal boring conditions 25 — 35 30 — 42 Poorly consolidated sand/gravel 35 — 60 42 — 72 Lubrication fluid for microtunneling 50 — 60 60 — 72 Packaging BORE-GELfluid system is packaged in a 50-lb (22.7-kg) multiwall paper bag. The bag is sturdy, moisture resistant and easy to handle, store and transport. Availability BORE -GEL fluid system can be purchased through any Baroid Industrial Drilling Products Retailer. To locate the Baroid IDP retailer nearest you contact the Customer Service Department in Houston or your area IDP Sales Representative. Baroid Industrial Drilling Products Product Service Line, Halliburton 3000 N. Sam Houston Pkwy. E. Houston, TX 77032 Customer Service (800) 735-6075 Toll Free (281) 871-4612 Technical Service (877) 379-7412 Toll Free (281) 871-4613 12 Sheet `� of Project TUFot�l►� l�z�n3 Ctake�/?�firhr���'ika-w� E3RA Subject �cCk&A (�� pa-gi-O , Job Number -r�clos� Computed By kLp,) Date 9-`I -il Checked By Pacl,- wCk I( (np- cx-fry+ t-z a--,. s an suds repa--F byr sl��e a � � lie d', �T:5,f rs 4'16 �, �- l rviQ XVw,(-)vn ('orce "a ©p a I`1 /`� (5t oc•e e_rmSeoA-ta ft,�� -uVvi 6 v� v.��� 0sc� cr0 0 lets c:-P ro� ) i�5+Q A c-e 9 �e�-f e,- -f G� a v� -firs �r� cues r�^C � c l Jrv- ,e plak-s aeepe,- Q•l back ©v- cJ-8 ck pf e , 13 �E"+6 c�� Surcharge Load = 200 psf (construction equipment) cral.l. . .. „ J, - ,I, I 5 Sheet Pile — — 10 concrete Slab . 15 ,w 20 q a c) 25 ({�� 30 .`-- 35 ` 6p .40 .(Mot -To -Scale) Passive Soil Pressures (psf): 9p = 3,400 Motes: oa2 0 va3 Active Soil, Pressures (psf): gal = 60 ga2 = 430 ¢a3 = 900 1. Hydrostatic pressure should be added to the lateral load qn the sheet pile wall. 2. All pressures in pounds per square feet (psf). 3, Passive pressures include a safety factor of 1.5. 4. Recommended sheet pile embedment depth, = 1.6 times excavation depth b. A subgrade reaction modulas of 40 pounds per cubic inches (poi) can be used for the soil above mudline. S&EE Job no. 912 Piure 4 Soil Pressures on Sheet Pile Wall 14 bake Avenue S Storm Improvement, Renton, WA provided to Builders Exchange of WA, Inc. [-or usage Conditions Agreemeni see www.Dxwa.com Aiways venry acme Operation and Manual 481750 48154-750 48160-750 481950 48160-950 48160- 1.35MXH D Part Number 199-0015 Version 1.0.0 Aco Inc. M11 111V. I1Lb 1 CbUT V UU PG 15 Barbco_ MAJOR MACHINE COMPONENTS AWARNING! Two sets of lift points are provided. The upper set, located on the rack, is used to lift the power package ONLY! It is NEVER to be used to lift the entire machine. A second set of lift points is located on the base push unit. They can be used to lift either the base unit alone or the entire machine. DESCRIPTION OF MAJOR MACHINE COMPONENTS OF HORIZONTAL EARTH BORING MACHINES The location of major machine components and normal accessories of Barbco's horizontal earth bor- ing machines are shown in the diagram. A - POWER PACKAGE: This portion of the machine contains the engine, clutch, transmission and torque hub. It also includes the fuel tank, hydraulic oil tank, filters, hydraulic pumps and operating controls, final drive, spoil paddles and optional winch. B - MASTER CASING PUSHER: Contains the spoil chamber, spoil door and casing attachment, as needed for smaller diameters of casing. C - BASE PUSH UNIT: Included in this section are the base frame unit, thrust cylinders, push bar, hook rollers, operators platform and optional Rapid Travel System. 14 Component Description PG 16 Barbco,_ D - MASTER TRACK: This section of track is furnished with the machine and is always used as the rearmost track section. It has a thrust plate bolted to the end of the track. The master track is 12 ft. long and is comprised of a 10 ft. standard extension track and a 2 ft. pup track. E - EXTENSION TRACK: These are additional sections of track to be bolted to the master track and to each other to allow installation of casing sections. Two sections of extension track along with the master track are furnished with each machine. Optional extension tracks can be added to allow for the installation of longer casing sections. F - MASTER SADDLE: Apparatus which rests on the track in front of the boring machine to cradle the casing and auger. G - LIFT POINTS (4) - POWER PACKAGE: Used to attach spreader bar chains and raise or lower the Power Package ONLY! NEVER use these points to lift the entire machine. H - LIFT POINTS (4) - BASE PUSH UNIT: Used to attach spreader bar chains and raise or lower the entire machine or the Base Push Unit only. - LIFT SLING: Lifting apparatus used to raise or lower the Power Package, Base Push Unit or entire machine. J - CASING ATTACHMENT: Optional accessory used to reduce the size of the Master Casing Pusher to accommodate smaller casing diameters. K - TRACK PICK-UP LOCATIONS: Lift Points on the Master and Extension Tracks to allow the use of the spreader bar for raising or lowering. L - SADDLE ATTACHMENT. Optional accessory used in conjunction with the casing attachment to cra- dle smaller casing diameters and auger. �i M - PUSH BAR: Contains the push bar dogs and is attached to the thrust cylinders. It also receives the machine thrust transferring it to the track and into the push plate and backstop. N - SPOIL EJECTORS: Paddles bolted to the front drive used to expel spoil from the spoil chamber out the master casing pusher spoil door for removal. O - FRONT DRIVE: Driveline component used to transmit power from the Power Package to the auger string and cutting head. P - FRONT DRIVE ADAPTER: Interchangeable replaceable Male Hex by Female Hex Component used to connect the Front Drive to the auger string which can also be used to increase or decrease auger hex sizes. Q - 2 FT. PUP TRACK: Short Two foot long track section used in conjunction with the master track and is bolted between the push plate and master track. R - PUSH PLATE: Solid Steel crossmember bolted to the 2 ft. pup track to stabilize track assemblies and provide support for thrusting. S - PLATFORM STEP: Operations area for the machine operator to control and monitor boring opera- tions. It is intended for the operator only. Component Description 15 PG 17 :f• I d •Iat• ■ems - � -., .� _��•- �;�� Barbco... DESCRIPTION OF MINOR MACHINE COMPONENTS OF HORIZONTAL EARTH BORING MACHINES A - FUEL GAUGE: Displays fuel level in Fuel Tank. B - RETURN FILTER SERVICE INDICATOR: Displays condition of filter. C - RETURN FILTER: Traps particles in return oil. D - HYDRAULIC TANK BREATHER/FILTER: Allows tank to breath without allowing contaminates in. E - TEMP. & HYD. FLUID LEVEL GAUGE: Displays Hydraulic Oil Temperature and Reservoir Fluid Level. F - REMOTE GEARSHIFT: The earth boring machine is equipped with a 5-speed with reverse mechan- ical transmission. The shifting pattern is shown on a label in the operator's view. Operation in first through high gears will cause the auger to rotate FORWARD, or clockwise as viewed from the rear of the machine. Reverse gear will cause the auger to rotate in REVERSE, or counterclockwise as viewed from the rear of the machine. Drive torque is determined by the gear selected. The highest torque is in first and reverse gears. Remote linkage for operator comfort in lift kit modes. G - EXHAUST EXTENSION: 30" extension to help remove exhaust fumes away from operator. H - HOOK ROLLER: Device located at each corner of the base push unit used to support and anchor the machine to the track. - HYDRAULIC WINCH: Used to rapidly retract the machine once it is free from the auger string after pushing a piece of casing. It is NEVER to be used for any other purpose. J -SWIVEL BOLT HOLD DOWN: Used to anchor the Power Package and Master Casing Pusher to the Base Push Unit and Power Package respectively. K - CONTROL PANEL: Location of control and gauges convenient to the operator. L - TRACK BRAKE: 48/750, 48/950 and 48/60-1.35MXHD Series Earth Boring Machines are equipped with a track brake that holds the machine on the track when the engine is idling and non -boring oper- ations are being done. The track brake should be used whenever the operator is away from the oper- ator's station. M - CLUTCH LEVER: Engages and disengages power to the drive -line. Pull and hold to disengage power. N - FILLER BREATHER: Vent and filter of reservoir air. Component Description 17 PG 19 18 Barbco,. Hydraulic Push Bar with Dog Locked into Track and identification of Push Bar Cover Plate. Component Description 3) 8" hydraulic rams PG 20 Barbco_ DESCRIPTION OF MINOR MACHINE COMPONENTS OF HORIZONTAL EARTH BORING MACHINES (Continued) O - SWIVEL BOLT HOLD DOWN: Used to anchor the Power Package and Master Casing Pusher to the Base Push Unit and Power Package respectively. P - TRACK WIPERS: Adjustable rubber wipers located at each corner of the base push unit to clear debris from the contact surface of the track assembly. Q - HOOK ROLLER: Device located at each corner of the base push unit used to support and anchor the machine to the track. R - RAPID TRAVEL SYSTEM: Used to rapidly advance and retract the machine once it is free from auger string and casing. It is NEVER to be used for any other purpose. S - TRACK BRAKE: 48/750, 48/950 and 48/60-1.35MXHD Series Earth Boring Machines are equipped with a track brake that holds the machine on the track when the engine is idling and non -boring oper- ations are being done. The track brake should be used whenever the operator is away from the oper- ator's station. T - PUSH BAR COVER PLATE: Shield to protect hydraulic push bar dog cylinder. Remove to clean and maintenance cylinder and dogs. U - QUICK DISCONNECTS: Spring loaded, locking hydraulic couplers used to connect and disconnect hydraulic power to the base push unit. V - LOCKING PIN: Locks the dogs into push bar. W - DOG ALIGNMENT SENSOR: Horizontal alignment of push bar dogs engagement into the track. X - PUSH BAR DOGS: Used to engage or disengage the push bar from the track assembly. Component Description 19 PG 21 Barbco- OPTIONAL 60" PUSH KIT An optional 60" Push Kit is available for the Barbco 48 series horizontal earth boring machine. The optional push kit increases the machine centerline for the installation of a 60" diameter master casing pusher and master saddle. 22 Component Description PG 22 Bd1b[O PUSH KIT COMPONENT DESCRIPTION A - MASTER CASING PUSHER: Contains the spoil chamber, spoil door, and casing attachment as needed for smaller diameters of casing. MASTER SADDLE (not shown): Apparatus which rests on the track in front of the boring machine to cradle casing and auger. B - RISER BLOCKS: Spacers affixed to each corner of the base push unit raising the machine center- line. C - EXTENSION SPOIL PADDLES: Bolt on plates which extend the original spoil ejectors to accommo- date a larger spoil chamber. D - SWIVEL HOLD DOWN EXTENSION BOLT: Replaces the standard bolt to accommodate the increased centerline of the machine. E - BASE PUSH UNIT EXTENSION RAIL: Tie the front and rear riser blocks together and extend the height of the base push unit providing more stability. F - CASING GUIDES: To help in casing installation. G - LOCKING SAFETY DOOR: Keeps door from flying open as rock and dirt are moved with spoil paddle. Component Description 23 PG 23 Barbco Boxing Machine Set Up DESIGNING THE JOB AND PREPARATION OF THE ENTRANCE PIT When the job is in the planning stage, provide enough room for safe loading and unloading of equip- ment, and for spoil removal. Accidents are less likely to occur at sites that are open and kept clear of debris. In most instances, an entrance pit will be required at the approach side of the bore. The dimensions of the pit floor required to install 20 feet (6.1 m) sections of casing, are found in the Entrance Pit Dimen- sions Chart. These dimensions will provide the most convenient and safest working conditions. They can be reduced but at the expense of efficiency and production. It is the responsibility of the owner to make a safe pit that is in accordance with the rules set forth in the (OSHA) Code of Federal Regulations 29. There are specific requirements for pit construction, protec- tion, barricades, traffic control, installation and type of ladders used in the pit and personal safety equip- ment. Barbco, Inc. recommends that the owner become familiar with the requirements of the (OSHA) Regulations CFR29. Information can be obtained from your Regional Department of Labor Office. The floor of the pit must be aligned with the proposed casing grade. It must also be solid enough to sup- port the equipment being used without settling. A base of crushed stone should be used to prevent settling. The use of planking under the tracks is recommended and should be allowed for when bringing the floor up to grade. For long and/or critical bores the use of a concrete base is recommended. The boring operation requires that a square and secure backstop be provided for the track push plate. The thrust for the entire bore is transferred through the track to the backstop. Should the backstop fail dur- ing the bore campaign, valuable time will be lost in rebuilding. The backstop should be designed to with- stand 1-1/2 to 2 times the maximum thrust of the boring machine being used. Barbco, Inc. strongly recommends using the services of a competent engineer to assist in the pit base/backstop design. On all bores, it is recommended that a steel plate be used between the track push plate and the back- stop. For larger diameter and longer bores, driven sheeting, or a poured concrete pad should be consid- ered. Experience and soil conditions will dictate the best method. A GOOD BASE AND A SECURE BACKSTOP ARE ESSENTIAL FOR ALL BORES. Refer to the Ground Conditions Chart in the Appendix section for base and backstop recommendations. The possibility of flooding always exists during the boring operation. The location of a pit sump pump for dewatering should be considered during the design of the pit. Set Up 27 PG 24 Barbco. w TO INSTALL 20 FT. (6.1 m) CASING LENGTHS SEE PIT CHART FOR DIMENSIONS REQUIRED USING BARBCO HORIZONTAL EARTH BORING MACHINES. L INCLUDED IN CHART ENTRANCE PIT DIMENSIONS CHART MODEL CL S W L H in [cm] ft [m] ft [m] ft [m] in [cm] 24-100 Series 15 [38.1] 6 [1.83] 9 [2.74] 32 [9.75] 52 [132.1] 24-150 Series 18 [45.7] 6 [1.83] 9 [2.74] 34 [10.36] 52 [132.1] 30-200 Series 19 [48.3] 7 [2.13] 11 [3.35] 34 [10.36] 52 [132.1] 36-350 Series 22.5 [57.2] 7.5 [2.29] 12 [3.66] 34 [10.36] 59 [149.9] 36-500 Series 22.5 [57.2] 7.5 [2.29] 12 [3.66] 34 [10.36] 59 [149.9] 36-630 Series 22.5 [57.2] 7.5 [2.29] 12 [3.66] 34 [10.36] 59 [149.9] 48-750 Series 28 [71.1] 8 [2.44] 12.5 [3.81] 34 [10.36] 65 [165.1] 48-950 Series 28 [71.11 8 [2.44] 12.5 [3.81] 34 [10.36] 65 [165.1] 48-1.35 Series 33.75 [85.7] 9 [2.74] 14 [4.27] 35 [10.67] 69 [175.3] 60-1000 Series 34.75 [88.3] 9 [2.74] 14 [4.27] 36 [10.971 72 [182.9] 28 Set Up PG 25 Barbco. SETTING AND ALIGNING THE TRACK The most critical part of the bore is the setting of the machine track on line and grade. If the alignment is not right when you start, it is not likely to improve. THE MACHINE AND THE TRACK SECTIONS ARE DESIGNED TO BE PLACED SEPARATELY. ALWAYS USE BALANCED LIFT POINTS. AWARNING! Always use correct lifting devices and NEVER hoist or transfer loads over personnel! Keep from welding to top of track rails or premature failure of machine rollers and sensor will occur. Lift and place the master track in the pit with the push plate against the backstop. Use a string and plumb bob to align the master track with the line of the proposed bore. Note that the track sections are numbered at each end. Extension tracks are installed so that adjoining ends have the same number. Install the extension tracks, aligning the top of the joints and bolting them together using bolts in ALL holes. Before setting the machine, make a final check of the line and grade. Set Up 29 PG 26 Barbco_ SUGGESTIVE JOB SITE START UP CHECK LIST Barbco Inc. recommends that the following items be checked before starting the bore. 1) JOB SETUP A) Pit walls adequately sloped or sheeted for safety in accordance with (OSHA) CFR29 B) Machine & Casing on Line C) Machine & Casing on Grade D) Water Level located with enough chart to accommodate grade for length of bore E) Pit Sump Pump installed and operating properly F) Pit Area cleaned up 2) CUTTING HEAD & CASING A) Measure and Record Outside Cutting Diameter Over Wing Cutters B) Measure and Record Collapsed Head Clearance inside Casing C) Cutting head teeth in condition for job D) Start Bentonite Pump -flow at leading end OK E) Mark casing in one foot increments starting at leading end 3) BORING MACHINE - Refer to Maintenance Section A) Fluid levels in Machine B) Engine crankcase Oil C) Transmission Gear Lube D) Gearbox Gear Lube E) Winch Gear Oil F) Hydraulic Oil G) Diesel Fuel H) Winch locked out and cable wound 1) Hook Rollers Down & Locked J) Spoil Door Closed 4) JOB SAFETY A) CREW HAVE ANY QUESTIONS REGARDING SAFETY OR PROCEDURES WITH EQUIPMENT BEING USED B) Refer to Safety Section of this Manual and Read and Understand it Completely Set Up 35 PG 27 Barbco... CASING INSTALLATION PREVIEW "Collaring" is the first operation in beginning a bore. The objective is to start the cutting head into the ground without lifting the casing out of the saddle. This is done rotating at low RPM's and using a slow thrust advance. When about four feet of casing has entered the ground, SHUT DOWN the engine, remove the saddle, and check the line and grade the casing. If the casing is not running true, back it out and start again. The success of the bore depends upon the line and grade of the first section of casing. After the first section of casing has been installed in the ground, stop advancing and clean the cas- ing by rotating the auger until all the spoil is removed. (Exception: In sandy conditions or other runny materials, DO NOT clean the casing as this may create a void. Check the Ground Conditions Charts.) SHUT DOWN the machine and remove the auger pin from the spoil chamber. IT IS AN ABSOLUTE RULE THAT THE MACHINE IS TO BE SHUT DOWN BEFORE THE SPOIL DOOR IS OPENED TO REMOVE THE PIN FROM THE AUGER DRIVE. Unbolt and remove the torque plates, then move the machine back to the rear of the track and SHUT IT DOWN. Lower the next section of casing and auger into position. Hold and align the casing until the augers at the face are "timed", flight -to -flight, and couple the hex joint. Block under the casing for support and relax the lifting cables so there is no tension. Block the opening between the casing, and install the auger pin. When the coupling has been secured, remove the blocking, then weld tabs on the new cas- ing at 11 and 1 o'clock positions. Clear the area, and advance the casing over the auger with the boring machine. Use a heavy wood blocking between the machine and the casing and DO NOT rotate the auger during this operation. Align the new casing with the installed casing by resting the tabs on top of the installed casing. Block the new casing at the machine end and relocate the lift back to the machine end. Align the two casing using 4' (1.2 m) minimum length straight edges along the top and sides. If the new casing is in line with the installed casing and seriously out of line at the machine end, the problem is in the installed casing and must be corrected. Continuing the bore will probably result in poor or unacceptable align- ment of the completed casing installation. The new section of casing is NEVER installed in the machine until the welding is complete. Tack the two casings together and fully weld. Start the machine and align the drive coupling with the auger hex and couple the drive. The operation may require the spoil door to be open and a worker to direct the operator to align the hex coupling. The use of a flashlight or mirror will allow the worker to be well away from the spoil chamber during the alignment. SHUT DOWN the machine and install the auger pin. Secure the casing at the machine by welding torque plates to the casing and bolting to the Master Casing Pusher. Add the water and bentonite lines if being used. It is important that each new section of casing be secured at the master casing pusher. This not only prevents the casing from turning, (which maintains the accuracy of the Water Level), it also reduces the hazard of the machine upsetting if the auger or head hangs up while boring. The weight of the casing and the added resistance in the ground, will add to the stability of the machine. Clear the area, start the machine, and install the casing. Con- tinue the process until the bore has been completed. If it becomes necessary to remove the cutting head during the bore to remove an obstruction or to service the cutting head — refer to "REMOVING AND INSTALLING AUGER WITH CUTTING HEAD ATTACHED". Casing Review 45 PG 28 Barbco- Appendix GROUND CONDITIONS CHART Wet Runny Sand Wet Stable Sand Dry Sand Dry Clay Wet Clay Small Gravel Auger Speed Slow Fast Slow Optional Optional Optional Rate Of Penetration Fast Fast Slow Optional Optional Optional Cutting Head BBC-25 Sand BBC-25 BBC-25 BBC-25 BBC-25 BBC-35 Wing Cutters No No No Yes Optional Yes Head Position Inside Inside Inside Flush Flush Outside Bentonite Yes Yes Yes Yes Yes Yes Water Inside No No No Yes Yes Yes Band Yes Yes Yes Yes Yes Yes Bore Continuous Yes Yes Yes Optional Optional Optional Clean Casing Pack Pack Pack Clean Clean Clean Pit Base Concrete Stone Optional Optional Stone Optional Backstop Concrete Concrete Concrete Steel Steel Steel GROUND CONDITIONS CHART Hard Pan Large Gravel Small Boulders Soft Solid Rock Hard Solid Rock Land or Railroad Fill Auger Speed Slow Slow Slow Slow Slow Cautious Rate of Penetration Medium Slow Slow Slow Slow Slow Cutting Head BBC-75 BBC-CT2 BBC-35 BBC-75 BBC-35 BBC-45 BBC-50 BBC-35 Wing Cutters Yes Yes Yes Yes Yes / No Yes Head Position Outside Outside Outside Outside Outside Outside Bentonite No No No No No No Water Inside Yes No No No Yes Yes Band Yes Yes Yes Yes Yes Yes Bore Continuous Optional Optional Optional Optional Optional Optional Clean Casing Clean Clean Clean Clean Clean Clean Pit Base Optional Optional Optional Optional Concrete Concrete Backstop Steel Steel Steel Concrete Concrete / Steel Concrete OVER,,$c $%j a F �i '� ' ��1 1 �r r �l ''y a' Appendix E-7 PG 29 Barbco- 48-750 Series Models: 48-750, 48/54-750, 48/60-750 SPECIFICATIONS POWER TRAIN HYDRAULIC SYSTEM ENGINE: PUMP: Deutz Turbocharged BF61-914C Air Cooled 6 cyl. #25 Oil Gear 5000 PSI (Continuous) 5800 PSI Direct Injected Diesel with Electric Start 160.5 HP (Intermittent) Pressure Compensated Load @ 2500 RPM, 516 Ft. Lb. (699 N-M) Peak Torque Sensing System, Axial Piston Pump, 38 GPM @ @ 1600 RPM 2300 RPM CLUTCH: 13 Inch (330 mm) Diameter TRANSMISSION: Eaton Fuller FS-4205A - 5-Speed 1 st Gear 8.05 : 1 Ratio 2nd Gear 4.35 : 1 Ratio 3rd Gear 2.45 : 1 Ratio 4th Gear 1.48 : 1 Ratio 5th Gear 1.00 : 1 Ratio Reverse 8.05 : 1 Ratio CYLINDERS: —� Three 8 Inch (203.2 mm) Bore X 36 Inch (914.4 mm) Stroke 753,990 Lb. (3,353,748 N) Thrust (Continuous), 874,628 Lb. (3,890,347 N) Max Thrust (Intermittent) MAXIMUM OUTPUT TORQUES AND SPEEDS: 1st Gear 225,136 Ft. Lb. (305,287 N•m) & 4 RPM 2nd Gear 121,657 Ft. Lb. (164,967 N•m) & 8 RPM 3rd Gear 68,520 Ft. Lb. (92,913 N•m) & 12 RPM 4thGear 41,391 Ft. Lb. (56,127 N•m) & 20 RPM 5th Gear 27,967 Ft. Lb. (37,924 N•m) & 30 RPM Reverse 225,136 Ft. Lb. (305,284 N•m) & 4 RPM GEAR BOX: Fairfield #20 54.2 : 1 Ratio AUGER DRIVE: 5 Inch (127 mm) Hex FILTERS: Suction 100 Wire Mesh Washable SST Return 10 Micron Replaceable Element DIMENSIONS: Work Range 12 to 48-54-60" (305 to 1219-1372- 1524 mm) Centerline 28,33,37.5" (711-838-952 mm) Height 60-63-67" (1524-1600-1701 mm) Width 60 Inch (1676 mm) Length 144 Inch (3.66 m) WEIGHTS: Base Unit - Split Machine Power Package - SP Machine Casing Pusher 48" Casing Pusher 54" Casing Pusher 60" Master Track Extension Track Specifications subject to change. 6,425 Lb. (2914 kg.) 6,400 Lb. (2903 kg.) 1,185 Lb. (538 kg.) 1,265 Lb. (574 kg.) 2,000 Lb. (909 kg.) 2,530 Lb. (1148 kg.) 1,875 Lb. (850 kg.) Barbco Inc. Manufacturing Horizontal Earth Boring Machines • Tunnel Equipment • Directional Drills • Tooling 315 Pekin Rd., S.E. • East Canton, Ohio 44730-9462 • Phone 330-488-9400 • Toll Free 1-800-448-8934 • Fax 330-488-2022 email: info@barbco.com • Web Site: www.barbco.com ge Appendix PG 30 Barbco., 48-950 Series Models: 48-950, 48/60-950 SPECIFICATIONS POWER TRAIN ENGINE: Deutz Turbocharged BF61-914C Air Cooled 6 cyl. Direct Injected Diesel with Electric Start 160.5 HP @ 2500 RPM, 516 Ft. Lbs. Peak Torque @ 1600 RPM CLUTCH: 13 Inch (330 mm) Diameter TRANSMISSION: Eaton Fuller FS-4205A - 5-Speed 1st Gear 8.05 : 1 Ratio 2nd Gear 4.35 : 1 Ratio 3rd Gear 2.45 : 1 Ratio 4th Gear 1.48 : 1 Ratio 5th Gear 1.00 : 1 Ratio Reverse 8.05 : 1 Ratio MAXIMUM OUTPUT TORQUES AND SPEEDS 1 st Gear 225,136 Ft. Lb. & 4 RPM 2nd Gear 121,657 Ft. Lb. & 8 RPM 3rd Gear 68,520 Ft. Lb. & 12 RPM 4thGear 41,391 Ft. Lb. & 20 RPM 5th Gear 27,967 Ft. Lb. & 30 RPM Reverse 225,136 Ft. Lb. & 4 RPM GEAR BOX: Fairfield #20 54.2 : 1 Ratio AUGER DRIVE: 5 Inch (102 mm) Hex HYDRAULIC SYSTEM PUMP: #25 Oil Gear 5000 PSI, (Continuous), 5800 PSI (Intermittent) Pressure Compensated Load Sensing System, Axial Piston Pump, 38 GPM @ 2300 RPM CYLINDERS: Three 9 Inch Bore x 36 Inch (914.4mm) Stroke, 1,106,000 Ib. Max Thrust DIMENSIONS: Work Range 12 to 48-54-60" (305 to 1219-1372- 1524 mm) Centerline 28,33,37.5" (711-838-952 mm) Height 60-63-67" (1524-1600-1701 mm) Width 60 Inch (1676 mm) Length 144 Inch (3.66 m) WEIGHTS: Base Unit Power Pack Casing Pusher 48" Casing Pusher 54" Casing Pusher 60" Master Track Extension Track Specifications subject to change. 6,425 Lb. (2914 kg.) 6,400 Lb. (2903 kg.) 1,185 Lb. (538 kg.) 1,265 Lb. (574 kg.) 2,000 Lb. (907 kg.) 2,530 Lb. (1148 kg.) 1,875 Lb. (850 kg.) Barbco Inc. Manufacturing Horizontal Earth Boring Machines • Tunnel Equipment • Directional Drills • Tooling 315 Pekin Rd., S.E. • East Canton, Ohio 44730-9462 • Phone 330-488-9400 • Toll Free 1-800-448-8934 • Fax 330-488-2022 email: info@barbco.com • Web Site: www.barbco.com Appendix M PG 31 Barbco_ 48-1.35 Series Models: 48-1.35, 48/60-1.35MXHD SPECIFICATIONS POWER TRAIN HYDRAULIC SYSTEM ENGINE: PUMP: Deutz BF61_914C Turbocharged — Charge Air #25 Oil Gear 5000 PSI (Continuous) 5800 PSI Cooled — 6 Cylinder. Air Cooled Diesel 185 HP (138 (Intermittent) Pressure Compensated Load kw) @ 2300 RPM Continuous Duty Rating 516 Ft. Sensing System, Axial Piston Pump 38 GPM @ Lbs. (700 N-M) Maximum Torque @ 1600 RPM 2300 RPM CLUTCH: CYLINDERS: Three 10 Inch Bore x 5.5 Inch Rod x 36 Inch 13 Inch (330 mm) Diameter Stroke Hydraulic Cylinders Maximum 1,350,000 TRANSMISSION: Lbs. Thrust @ 5,800 PSI Eaton Fuller FS-5205A - 5-Speed 1 st Gear 7.52 : 1 Ratio 2nd Gear 4.35 : 1 Ratio 3rd Gear 2.54 : 1 Ratio 4th Gear 1.52 : 1 Ratio 5th Gear 1.00 : 1 Ratio Reverse 6.27: 1 Ratio MAXIMUM OUTPUT TORQUES AND SPEEDS: 1st Gear 155,213 Ft. Lb. (210,601 N•m) & 8 RPM 2nd Gear 89,784 Ft. Lb. (121,824 N•m) & 13 RPM 3rd Gear 52,426 Ft. Lb. (71,134 N•m) & 22 RPM 4thGear 31,373 Ft. Lb. (42,568 N•m) & 38 RPM 5th Gear 20,640 Ft. Lb. (28,005 N-m) & 58 RPM Reverse 129,413 Ft. Lb. (175,594 N•m) & 9 RPM GEAR BOX: BBC #50 40 : 1 Ratio AUGER DRIVE: 5 Inch (127 mm) Hex FILTER: 10 Micron Absolute Replaceable Element DIMENSIONS: Work Range 12 to 48-54-60" (305 to 1219-1372- 1524 mm) Centerline 33-3/4"-37-3/4"-41-3/4" (857.25- 946.15-1060.45 mm) Height 66"-70"-74" (1674.4-1778- 1879.6 mm) Width 72 Inch (1828.8 mm) Length 156 Inch (3962.4 mm) 1 TJ41VMk1&13 Base Unit 10,000 Lb. (3719 kg.) Power Package - (Estimated) 8,100 Lb. (3583 kg.) Casing Pusher 48" 1550 Lb. (680 kg.) Casing Pusher 54" 1700 Lb. (748 kg.) Casing Pusher 60" 1950 Lb. (884 kg.) 13 Ft. Master Track 4600 Lb. (2140 kg.) 10 Ft. Extension Track 3520 Lb. (1623 kg.) Specifications subject to change. Barbco Inc. Manufacturing Horizontal Earth Boring Machines • Tunnel Equipment • Directional Drills • Tooling 315 Pekin Rd., S.E. • East Canton, Ohio 44730-9462 • Phone 330-488-9400 • Toll Free 1-800-448-8934 • Fax 330-488-2022 email: info@barbco.com • Web Site: www.barbco.com 92 Appendix PG 32 Barbco Inc. I Page Under Construction Attachment B Augers Page 1 of 2 Home News Contact Us Links Fun Stuff Mission Statement Rentals Yard Sale Financing Products Auger Our standard auger is built on Drawn Over�, Mandrel (D.O.M.) tubing` i with 1/2" flights and3 f 4140 shanks. All auger - k 36 and larger comesr with a patented box gusset for extra T reinforcement. �, 11 �'x r For those tough jobs Barbco offers EXTREME heavy duty auger. The strongest most reliable heavy duty auger n the industry. With 10" O.D. D.O.M. tubing and 5/8" thick wall; Extreme Heavy -Duty 5" Hex Bushing and a patented Box Gusset, Barbco has raised the bar in auger strength and dependability. scia i'4'n i xFiS+4� E �t' d 4x17 cxt w.g W' M . 5%5' W ox, M. 5" Hex Tubing Comparison 9 Su iv PG 33 http://barbco.com/auger.html 9/2/2011 Attachment C Steering Head & Water grade indicator. Bairbcoll. STEERING HEAD KIT AND WATER GRADE INDICATOR MANUAL BarbCo.. 1526 Henry Avenue, S.W. Canton, Ohio 44706 (330) 456-8383 ■ Toll -Free U.S. and Canada (800) 448-8934 ■ Fax (330) 456-8396 PG 34 LIST OF MATERIALS FOR LEAD PIECE OF CASING 1 pc. Casing 19'-10" long 1 Barbco Steering Head Kit 1 Set Steering Rod Ends 1 pc. 3/4" SCH 80 Black Pipe (Steering Rod Pipe) 1 pc. 1 1/2" SCH 40 Black Pipe 0 O m OO 2 pc. 1/2" SCH 40 Black Pipe 1 - 1 1/2" Pipe Nipple 8" long 1 -1 1/2" x 1 1/2" x 3/4" Pipe Tee 1 -1 1/2" Pipe Cap 1 - 3/8" x 4" Over Cut Ring j ..`..a A. + r r s+ ,11 STEERING HEAD COMPONENTS Water Level Sensing Head ® Optional Torque Master Ball & Tail for Side Hinge ® Side Mounts for Torque Master Cover Plate for Ball & Tail ® Steering Knuckle Skid Plate Steering Rod Ends ® Rear Mounts for Steering Knuckle ® Front Mount with Pin for Steering Knuckle HAND TOOLS NEEDED TO BUILD STEERING HEAD 1 - 24" Carpenter Square 1 - 25' Rule 1 - 4' Level 1 - Pipe Wrap Around 2 - Pieces Soap Stone 2 - 8" C-Clamps 2 - Pipe Wrenches 1 - Can Pipe Dope 1 - Welding Machine with Accessories 1 - Set Torches with Accessories 1 - Electric Hand Grinder 1 - Pipe Cutter 1 - Pipe Threader 1/2" & 1-1/2" die 1 - 2 lb. Hammer PG 35 STEP NO I Page 2 Locate center lines for top -bottom -sides. Then quarter the casing. END VIEW SPRING LINE TOP AND BOTTOM VIEW TOP VIEW 1.6 19, Id, 01 SIDE VIEW - SPRING LINE STEP NO 2 Mark a set back line around the circumference of the casing, determined by the O.D. size of the casing. Example Chart 1 T OD Casing -Set Back Line to be 12" 20" OD Casing -Set Back Line to be 20" 24" OD Casing -Set Back Line to be 24" 30" OD Casing and above, Set Back Line to be 30" �-24"-� EXAMPLE OF 24/ CASING ,SET BACK LINE - c TOP VIEW PG 36 Page 3 STEP NO 3 Mark a 2" x 6" rectangle on the top and bottom of the casing, using center lines and set back line. TOP AND BOTTOM VIEW 2�- /2�X 6��RECTANGLE < SET BACK LINE STEP NO 4 Mark a line from the comers of the rectangle to set back line on sides of casing. Both top and bottom section of casing. SET BACK LINE --- * SET BACK LINE-i TOP AND BOTTOM VIEW CORNER OF RECTANGLE TO SIDES OF CASING 'AT SPRING LINE SIDE VIEW CORNER OF RECTANGLE *TO SIDES OF CASING AT SPRING LINE SPRING LINE PG 37 STEP NO 5 Page 4 Cut out the 2" x 6" rectangles marked on top and bottom of casing. TOP AND BOTTOM VIEW CUT OUT 2HX 6" RECTANGLE IN SHADED AREA STEP NO 6 Cut out from spring line 2" over diameter of coverplate, within the lines drawn on both sides of casing. SIDE VIEW 2 CUT OUT SHADED AREA SPRING LINE fi CUT OUT SHADED AREA PG 38 Page 5 J {, — 2 STEP NO 7 Weld an overcut Bring around hwent. section of We'd back side-o Not providing overcut ring. PG 39 Page 6 STEP NO 8 Adjust the steering knuckle having a equal amount of turns in and out. This will allow the steering head when completed an equal amount of turns up and down. Align steering knuckle with front and rear mounts in place on top of casing. Using center line drawn for length of knuckle and front edge of cut out rectangle with weld line on body of knuckle. Weld front and rear mounts to casing. WELD LINE ON KNUCKLE TOP VIEW FRONT'MOUNT I / REAR MOUNTS WELD LINE ON KNUCKLE o SIDE VIEW FRONT MOUNT r REAR MOUNT SPRING LINE PG 40 Page 7 STEP NO 9 Side hinges are in two parts A. Ball and Tall e. Cover Plate for Ball and Tail Align the center of the ball to the set back line drawn around casing and horizontal spring line on side of casing. Once proper alignment is made, weld coverplate to front section of casing. Tail of ball to rear of casing. Once steering knuckle and side hinges are welded to casing, cut out remainder of marked lines from comers of rectangle to sides of casing, top and bottom. Ball Size Diameter 3" Diameter for casing 12" - 14"---------------- 112" thick stock 5-112' Diameter for casing 16" - 30"---------------- 3/4" thick stock 7" Diameter for casing 36" - 48"---------------- 3/4" thick stock 9" Diameter for casing 54" and 60"---------------- 1" thick stock STOCK TH(CKNESS A — BALL AND TAIL (:):::] n -->►1 1•------O 13 — COVER PLATE — Al WELD COVER PLATE TO FRONT SECTION ONLY on SIDE VIEW ALIGN BALL WITH SET BACK LINE AND SPRING LINE SPRING LINE WELD TAIL TO REAR SECTION OF CASING PG 41 Page 8 STEP NO IO Align the 318" x 4" x 8" skid plate to the bottom section of casing and weld to Front Steerina Section only. WELD TO FRONT SECTION ONLY BOTTOM VIEW 8 X 4�X 8~ SKID WELD TO FRONT SKID PLATE SECTION ONLY PLATE SIDE VIEW PG 42 Page 9 STEP NO II Pierce a 3/8" hole in casing for water level sensing head. Align hole in water level sensing head with 3/8" hole in casing and weld water level sensing head to casing. Connect 1/2" water level pipe. Cut a slot in casing 1/2" x 3" for water line to spoil. Cut a 4" long angle on 1/2" pipe and weld angle of pipe over slot in casing. (See Fig. A) TOP VIEW 3HOLE FOR WATER 8 LEVEL SENSING HEAD 5 Z, Sh-► i� �- SLOT,, IN CASING 3„ FOR j WATER PIPE 2 � PIPE TOP VIEW WATER SENSING HEAD 2 I" WATER PIPE 2 CUT AT ANGLE FIG A PG 43 STEP NO 12 Page 10 Make a steering rod using male and female steering rod ends with 3/4" SCH 80 pipe. The length of the steering rod will be from connected L end of steering knuckle to 1 1/2" pipe nipple. r t X1 Zo r W C11 n 13" FEM ALE LE ROD END Y STEP NO 13 • ATH }-MALE ROD END Cut a 1/2" slot, 3 inches back from the front end of 1 1/2" pipe. Place the steering Rod into the 1 1l2" pipe. Connect the steering rod to the steering knuckle. Slide the 1 1/2" pipe to the back of the steering knuckle. (Be sure the 112" slot is on the bottom). Secure the 1 1l2" pipe to the casing with a weld, approximately 1 foot from the back of the steering knuckle. it BOTTOM VIEW I%2 PIPE --�3�- SIDE VIEW CUT OUT SECTION SIDE VIEW YZX 1/2X%PIPE TEE I%2 NIPPLE 7=r \ f � WELD I i PIPE TO CASING l%2 CA PG 44 Page 11 OPTIONAL BARBCO TORQUE MASTER TOP VIEW PG 45 Page 12 BARBCO GRADE INDICATOR CHARGE WATER LEVEL iEN51NG HEAD VALVE SIGHT TUBE INLET WATER SUPPLY VALVE b SIGHT TUBE READ VALVE MEASUREMENTS IN HUNDREDS PG 46 Page 13 Welcome to the growing family of contractors who are using Barbco's Water Grade Indicator. This simple to use instrument gives you a time tested method of monitoring the grade of casing as it is being pushed into the ground. Your new Barbco Water Grade Indicator is as uncomplicated as we could make it, and its simple construction passes on to you lower cost while maintaining the high level of performance of more expensive instruments. HOW IT WORKS The Barbco Water Grade Indicator operates in the same way as the sight tube on a boiler. The small tube on the outside of the tank indicates the level of the water on the inside of the tank, as long as the indicator tube is connected to the same pressure as the inside tank. With the Barbco Water Grade Indicator, both ends of the system are vented to air pressure. A pit mounted control and indicator board is located at some convenient point in the pit, opposite of the spoil removal side of the pit. A clear plastic hose connects the pit mounted water grade indicator to the 1/2" water pipe running along the top centerline of the casing. Water is used to fill the system. The level of the water at the pit grade indicator will then show the level of the sensing head mounted on the end of the casing as it is pushed into the ground. A simple "topping off' procedure is used before each reading to assure that the system is full of water and reading properly. Careful attention to the following instructions and checking the instrument before readings will help assure good results. SET UP PROCEDURE 1. Welding the Water Level Sensing Head to Casing Drill or burn a 3/8" hole approximately 6" to 8" back from the front of the lead piece of casing, to vent excess water from the sensing head into the casing. Securely weld the sensing head over the 3/8" hole. 2. Securing the 1/2" Water Line to the Casing with straps. (Do not weld on 1/2" water line pipe). Weld strap clamps over the 1/2" water line pipe, to secure it to the casing. The threaded 1/2" water line pipe should end about 12" short of the end of the casing to allow hose connections ahead of the boring machine casing pusher. Mark the casing centerline at this point. This mark will be used to check for casing rotation at the end of each push. PG 47 Page 14 3. Locating the Pit Grade Indicator Secure a 2 x 6 or other reasonably flat piece of lumber to the wall of the pit at some convenient location, opposite the spoil removal side of the pit. Hang the pit grade indicator so that the middle of the indicator sight tube is about at a level with the top of the casing. Exact alignment of the pit grade indicator scale will be done during the filling and charging of the system. 4. Connecting the System Run a garden hose from the inlet water supply valve (bottom right) to the water supply. if a 55 gallon drum is being used for the water supply at ground level, (be sure to use clean water only), and keep the drum reasonably full of water throughout the bore. Connect the 30' clear plastic hose from the charge water level sensing head valve (bottom left) to the 1/2" water line pipe on the casing. Keep this line off the boring machine track, below the top of the casing, and long enough to reach when the push is finished. 5. Charging the System Step #1 - Open the charge water level sensing valve (bottom left). Close the sight tube read valve (center valve) open the inlet water supply valve (bottom right) and let water flow until it comes out of the water level sensing head, and no air bubbles exist in the clear plastic hose. Step #2 - Close charge water level sensing head valve (bottom left). Open sight tube read valve (center valve) and let water flow out of top of sight tube until no air bubbles exist. Close sight tube read valve (center valve) and inlet water supply valve (bottom right). All valves are now closed. Step #3 - Open charge water level sensing head valve (bottom left) and open sight tube read valve slowly (center valve) and allow water to level off for grade reading. Repeat steps #1, 2, and 3 for each grade reading. 6. Set grade indicator on pit mounting board so that zero on the scale is same as water level in the sight tube. The system is now ready for use. It is important that Steps #1, 2, and 3 be re -done before each reading and as new casing and 1/2" water pipe is added. 7. Adding New Casing and 1/2" Water Pipe As each push is completed, new casing and 1/2" water pipe are added. Check the casing center line mark for rotation. If the casing has rotated, grade readings will be in error by the amount of rotation. When new 1/2" pipe is added (use pipe cement only on all joints) and reconnect the clear plastic hose. Repeat charging the system (steps #1 thru #3). PG 48 Page 15 The following diagrams show how an incorrect reading and correct reading can be obtained: Fig. 1. System partially full of water and indicating INCORRECT READING, GRADE INDICATOR I " WATER LEVEL /2 SENSING HEAD WATER PIPE D FIG 1 I W____I_WATER LEV�g� I CASING CLEAR PLASTIC HOSE Fig. 2. System full of water and indicating CORRECT READING GRADE I NDICATOR WATER LEVEL Y2 SENSING HEAD FIG 2 --- -LEVEL LEVEL n< WATER PIPE D ---------- CASING CLEAR PLASTIC HOSE PG 49 Page 1e E 0 � � � co � � � � J ± R \ 3 �\ %� //ji G/(\� /7G5 82 0w Cc z 3\} 7 ; M # CL W � � � u $j N # Ri a LU �� 0) . � §� Ri CL \\ U) a = Page 17 PROBLEMS TO LOOK FOR /N SYSTEM A. Air bubbles in clear plastic line - Check all hose fittings for loose connections and bad washers. The system is taking in air. B. Water level sensing head plugged - If the water rises in the sight tube and flows out the top, the water level sensing head is probably plugged. Re -charge the system with the sight tube read valve closed (center valve). Full water pressure should open the sensing head. In some cases, an air compressor may be needed to unplug the line. If plugging conditions exist, you may want to bore with water running through the water level sensing head, then re -charge the system for grade readings. C. While taking readings be sure no one is stepping and/or standing on clear plastic hose. Be sure no one has moved pit grade indicator from its original setting. D. Always check for casing rotation. If casing has rotated, grade readings will be in error by the amount of rotation. E. If using a 55 gallon drum for water supply, be sure to keep it reasonably full with clean water. For any additional information call: (800) 448-8934 D.l. A plate will be welded on the end of each pipe that comes in contact with the casing pusher to keep the casing from rotating. PG 51 BENTONITE PUMP AND MIXER Model # MT750A-30EH Serial # WA9610- MICROTUNNELINC� INC BOULDER, COLORADO, USA 303-444-2650 Fax 303-444-0889 PG 52 1 2 3 13 4 5 6 7 8 9 10 11 12 1 750 GALLON MIXING TANK 2 ACCESS COVER, TOP OF TANK 3 VALVE, MIXING TANK SHUT-OFF TO CENTRIFUGAL PUMP 4 VALVE, FOR EXTERNAL PUMPING, SLURRY TANKS 5 VALVE, CENTRIFUGAL PUMP TO MIXING TANK AND MUD GUNS, SEE ITEM 31 6 CENTRIFUGAL PUMP 4" X 3", 1 7/8" PEDESTAL, I I" IMPELLER 7 VALVE, WATER SOURCE TO VENTURI MIXER 8 VALVE, VENTURI MIXER FEED SHUT-OFF 9 MOTOR, CENTRIFUGAL PUMP 15KW @ 380 VAC, 3 PHASE, 50 CYCLE 10 VALVE, VENTURI MIXER SUCTION SHUT-OFF 11 SIPHON ADJUSTORS, INSIDE VENTURI MIXER, 3 EACH 12 VENTURI MIXER 13 PLATFORM AND STEPS TO ACCESS COVER MICROTUNNELING; INC BOULDER, COLORADO, USA 303-444-2650 Fax 303-444-0889 PG 53 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 FILTER, HYDRAULIC POWER PACK MOTOR, HYDRAULIC POWER PACK, 7.5KW @ 380VAC, 3 PHASE, 50 CYCLE RESERVOIR, HYDRAULIC POWER PACK, 40 GALLON HYDRAULIC SWITCH, FOR 0-15 GPM OR 0-30 GPM VALVE, METERING FOR PLUNGER PUMP SPEED FLOW GAUGE, IN GALLONS PER MINUTE CONNECTOR DISCONNECT, CORD SET MOTOR, HYDRAULIC 2-SPEED FOR 0-15 GPM OR 0-30 GPM PUMP, PLUNGER 0-30 GPM @ 200 PSI OR 0-15 GPM @ 500 PSI ELECTRICAL PANEL, SYSTEM CONTROLS, 380 VAC RECIRCULATION LINE, (BY-PASS LINE) VALVE, ANTI -FREEZE CONTAINER VALVE, MIXING TANK SHUT-OFF TO PLUNGER PUMP CONTAINER, ANTI -FREEZE, VALVE, RECIRCULATION LINE SHUT-OFF GAUGE, SYSTEM PRESSURE VALVE, MIXER TANK FILL MUD GUNS, LOCATED INSIDE MIXER TANK, SEE VALVE 5 MICROTUNNELINC� INC BOULDER, COLORADO, USA 303-444-2650 Fax 303-444-0889 PG 54 1 2 3 4 5 6 7 8 9 10 11 12 13 III 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 INDEX 750 GALLON MIXING TANK ACCESS COVER, TOP OF TANK VALVE, MIXING TANK SHUT-OFF TO CENTRIFUGAL PUMP VALVE, FOR EXTERNAL PUMPING, SLURRY TANKS VALVE, CENTRIFUGAL PUMP TO MIXING TANK AND MUD GUNS, SEE ITEM 31 CENTRIFUGAL PUMP 4" X 3", 1 7/8" PEDESTAL, I I" IMPELLER VALVE, WATER SOURCE TO VENTURI MIXER VALVE, VENTURI MIXER FEED SHUT-OFF MOTOR, CENTRIFUGAL PUMP 15KW @ 380 VAC, 3 PHASE, 50 CYCLE VALVE, VENTURI MIXER SUCTION SHUT-OFF SIPHON ADJUSTERS, INSIDE VENTURI MIXER, 3 EACH VENTURI MIXER PLATFORM AND STEPS TO ACCESS COVER FILTER, HYDRAULIC POWER PACK MOTOR, HYDRAULIC POWER PACK, 7.5KW @ 380VAC, 3 PHASE, 50 CYCLE RESERVOIR, HYDRAULIC POWER PACK, 40 GALLON HYDRAULIC SWITCH, FOR 0-15 GPM OR 0-30 GPM VALVE, METERING FOR PLUNGER PUMP SPEED FLOW GAUGE, IN GALLONS PER MINUTE CONNECTOR DISCONNECT, CORD SET MOTOR, HYDRAULIC 2-SPEED FOR 0-15 GPM OR 0-30 GPM PUMP, PLUNGER 0-30 GPM @ 200 PSI OR 0-15 GPM @ 500 PSI ELECTRICAL PANEL, SYSTEM CONTROLS, 380 VAC RECIRCULATION LINE, (BY-PASS LINE) VALVE, ANTI -FREEZE CONTAINER VALVE, MIXING TANK SHUT-OFF TO PLUNGER PUMP CONTAINER, ANTI -FREEZE VALVE, RECIRCULATION LINE SHUT-OFF GAUGE, SYSTEM PRESSURE VALVE, MIXER TANK FILL MUD GUNS, LOCATED INSIDE MIXER TANK, SEE VALVE 5 MICROTUNNELING, INC BOULDER, COLORADO, USA 303-444- 2650 Fax 303-444-0889 PG 55 BENTONITE PUMP AND MIXER MIXING Mixing starts with the introduction of water via valve #7 or #30. It should be noted that water with a pH of 8.5 will yield best when mixed with sodium bentonite. Mixing with the introduction of water through valve #7 => Valve #7 open => Valve #8 and #10 closed => Introduce fresh water into valve #7. NOTE: Insure water is at a minimum pressure of 45psi (approx. 3 bar). to generate enough vacuum and mixing action. => Turn water source on, maintain pressure. => Slowly open valve #10. Position of valve will need to be determined as site conditions warrant. => A vacuum will be felt from within the venturi mixer, near the siphon adjusters. There are three siphon adjusters each with different size holes. The smaller the hole the slower the bentonite will be drawn, the best pre -mixing will be accomplished with the smallest size hole. Three sizes are included to account for varying site conditions. => Bentonite mixture should be determined prior to mixing (gallons vs. amount of bentonite, for a 1% through 6% solution, approximately). => Add bentonite by lifting bag and dropping into venturi mixer. NOTE: Within the top portion of the venturi mixer a bag cutter will pierce the bottom of bag and allow the bentonite to fall to the siphon adjusters and into the pre -mixing section. => Close valve #10 once the pre -determined amount of bentonite has been added. Keep the water ON to fill tank to desired level. CAUTION: Failure to keep venturi mixer dry will cause it to "plug". If in the event this happens valve #10 can be removed via three quick disconnect clamps, the interior can then be cleaned. Close valve #7 and #8. The bentonite is now pre -mixed and needs to be mixed or blended thoroughly. Open valve #3, #5. Valve #4 keep closed. Connect power cord to connector body #20. Energize power cable. => Turn ON the "Pump Switch" on the electrical panel #23. => Pre -mixed bentonite will be drawn through a 4" x 3" Pump and then forced through the "Mud Guns" located within the 750 Gallon Mixer. This combined action will create the necessary "shear" to completely blend the bentonite within minutes. The type bentonite used the pH of the water used and the rate of the initial pre -mix will determine the blend time. NOTE: Once mixed the blending operation should be stopped. => Turn OFF the "Pump Switch" on the electrical panel #23. MICROTUNNELING� INC BOULDER, COLORADO, USA 303-444-2650 Fax 303-444-0889 PG 56 Mixing with the introduction of water through Valve #28 => Open Valve #30. => Fill with water the 750 gallon tank to the desired level. => Open valve #3, #5, #8. Close valve #4, #7, #10. => Connect power cord to connector body #20. Energize power cable. Turn ON the "Pump Switch" on the electrical panel #23. Slowly open valve #10. A vacuum will be felt from within the venturi mixer, near the siphon adjusters. There are three siphon adjusters each with different size holes. The smaller the hole the slower the bentonite will be drawn, the best pre -mixing will be accomplished with the smallest size hole. Three sizes are included to account for varying site conditions. Increased vacuum can be accomplished by closing Valve #5 a small amount. Water pressure should be in the order of 45 psi (3 bar). to generate enough vacuum and mixing action. Bentonite mixture should be determined prior to mixing (gallons vs. amount of bentonite, for a 1% through 6% solution, approximately). Add bentonite by lifting bag and dropping into venturi mixer. NOTE: Within the top portion of the venturi mixer a bag cutter will pierce the bottom of bag and allow the bentonite to fall to the siphon adjusters and into the pre -mixing section. Close valve #10 once the pre -determined amount of bentonite has been added. Keep the centrifugal pump ON until valve #10 is closed. CAUTION: Failure to keep venturi mixer dry will cause it to "plug". If in the event this happens valve #10 can be removed via three quick disconnect clamps, the interior can then be cleaned. Open fully Valve #5. Close Valve #8. The bentonite is now pre -mixed and partially blended. It needs to be mixed or blended completely. Pre -mixed bentonite will be drawn through a 4" x 3" Pump and then forced through the "Mud Guns" located within the 750 Gallon Mixer. This combined action will create the necessary "shear" to completely blend the bentonite within minutes. The type bentonite used the PH of the water used and the rate of the initial pre -mix will determine the blend time. NOTE: Once mixed the blending operation should be stopped. Turn OFF the "Pump Switch" on the electrical panel #23. Transferrin1l bentonite throuf4h Valve #4, To Slurry Tanks =:> Open Valves #3, #4. Close Valves #5, #7, #8, #10. => Hookup hose to valve #4 and secure far end to desired fill area. => Connect power cord to connector body #20. Energize power cable. => Turn ON the "Pump Switch" on the electrical panel #23. => When tank is empty or desired amount of bentonite has been discharged, Turn OFF "Pump Switch" on the electrical panel #23. MICROTUNNELING� INC BOULDER, COLORADO, USA 303-444-2650 Fax 303-444-0889 PG 57 Plunger Pump General System Information • Bentonite delivery is accomplished by a 30 GPM rated plunger pump. A two speed hydraulic motor powering the pump delivers 0-15 GPM at 200 psi or 0-30 GPM at 500 psi. The Plunger pump has a rating of 3500 psi continuous working pressure but at a higher kW rating than is installed on this pump. It provides a positive displacement delivery of bentonite lubrication. Its relief valve is set at 200 psi and for normal system delivery should be adequate. For higher than the 200 psi setting re -adjusting the relief valve is required, located in the lower section of the by-pass line #24. A by-pass line enables continuous pumping of the plunger pump discharging into the mixing tank. A pressure gauge records system pressure while a flow gauge advises the GPM flow rate. • Pump and mixer may also be used as a test pump and can pressurize lines to 500 psi. • A anti -freeze provision has been incorporated to prevent the problems associated with extreme cold weather. • A load make and break power cable connector provides an electrical disconnect means while serving as a power cable. • Three lifting points are only for use when the mixing tank is empty. • The Hydraulic power pack has a 40 gallon capacity tank and uses a ISO 32 hydraulic oil. Temperature extremes either too hot or cold will require re-examination of oil types. • A switch close to the flow gauge will change the hydraulic motor on the plunger pump from slow to high speed, causing flow rates from 0-15 and 0-30 GPM. Plunger Pump Delivery • Open valve #26, #28, Close valve #25. • Connect power cord to connector body #20. Energize power cable. • Close plunger pump system delivery valve (not provided). • Turn ON the "Hydraulic Pump Switch" on the electrical panel #23. • Adjust valve #17 for either high (0-30 GPM) or low (0-15 GPM) system flows. • Adjust needle Valve #18 to throttle pump speed. Clockwise to lower • Bentonite will by-pass, slowly open system delivery valve then close Valve #28. delivery pressure will build to adjusted limits. • Blocked lines or a closed system delivery valve will cause pressure to build. • During pipe change overs open Valve #28 to place system to by-pass and close system delivery valve. CAUTION ♦ Hydraulic filter should be changed every 100 hours of operation or once per month. ♦ Hydraulic oil to be replaced each 300 hours of operation or 180 days. ♦ Hoses need to be checked for leakage or visible damage each day. ♦ All electric power and hydraulic pressure must be off prior to any work being undertaken. ♦ Plunger Pump must not be allowed to run dry or damage to the pump will occur. MICROTUNNELING� INC BOULDER, COLORADO, USA 303-444-2650 Fax 303-444-0889 PG 58 GROUT MIXING AND DELIVERY ►WARNING -------- - --- THIS MIXER WAS DESIGNED TO MIX AND DELIVER BENTONITE TO PIPE JACKING AND MICROTUNNELING PROJECTS. GROUT MAY BE MIXED BUT EXTRA CAUTION NEEDS TO BE EXERCISED. THE SUPPLIERS OF THE SYSTEM COMPONENTS HAVE ASSURED US THAT GROUT MIXING AND DELIVERY SHOULD NOT CREATE ANY PROBLEMS IF DONE PROPERLY WITH THE SUPPLIED COMPONENTS. BASIC PROCEDURES FOR MIXING AND DELIVERY OF BENTONITE ARE THE SAME WITH CERTAIN ADDED STEPS. SINCE OPERATION AND MAINTENANCE SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL IT IS IMPORTANT THEY BE FAMILIAR WITH THE MIXER AND ITS OPERATION. ALL CONCERNED NEED TO CONTRIBUTE TOWARDS GOOD COMMON SENSE PROCEDURES DURING AND AFTER GROUT MIXING. BELOW ARE SOME POINTS TO CONSIDER: 1. CLEAN-UP WHEN FINISHED IS VERY IMPORTANT. 2. GROUT SETTING -UP INSIDE THE MIXER AND ITS COMPONENTS CANNOT BE ALLOWED TO HAPPEN. CONTINUOS BATCH MIXING WITHOUT CLEANING COULD ALLOW THE GROUT TO SET UP. 3. A LOW SLUMP (THICK) GROUT MIX WILL PROBABLY HAVE MORE PROB- LEMS THAN A THINNER MIX. 4. PLENTY OF WATER FOR FLUSHING OUT THE COMPONENTS IS NEEDED. 5. MAINTENANCE PERSONNEL AND THEIR TOOLS NEED TO BE PRESENT IN THE EVENT A COMPONENT NEEDS DISASSEMBLY AND CLEANING. 6. PLUNGER PUMP AND CENTRIFUGAL PUMP SEAL KITS SHOULD BE ON HAND PRIOR TO GROUT MIXING. IF PUMPS LEAK AFTER THE GROUTING OPERA - TIN THEN THE SEALS NEED TO BE CLEANED OR REPLACED. 7 GROUT MIXED TOO THICK CAN CAUSE THE CENTRIFUGAL PUMP TO OVER- LOAD. 8. THE USE OF A RETARDING AGENT FOR THE GROUT IS RECOMMENDED GROUT MIXING EQUIPMENT REQUIRES EXTRA WORK TO KEEP IT OPERATIONAL THIS MIXER IS NO DIFFERENT, PLAN AHEAD! MICROTUNNELINC� INC BOULDER, COLORADO, USA 303-444-2650 Fax 303-444-0889 PG 59 TP-L4 SERIES 0 'k, M4,11 TO P CO R Put the World's brightest, most advanced alignment laser to work on your next job: • VVORLD'S 1ST ULTRA -VISIBLE GREENBEAmA • MRLD'S MOST ACCURATE GRADE AND LEVELING • MRLDS1ST SMARTUNE'R ALJTO-ALIGM1ff.NTS`6T • ALL IN THE MRLD'S TOUGHEST CAST ALUMNUM HOU%G @ w nw! %5asy, U4N_- 5X8;4k PG 60 It's time. Your solution to guarantee you'll get from here to there, Quickly, accurately and affordably. Topcorts TP-1-41 s,xies of aidnment iasers offer a combinatiw of leijure5 and technology that are prcrren to me~=t tFe ditmandi of contractors more than any o6er alityprnent l# sm- s on the market. Whether in the trenches, ovot thr top, or L3-X.,r guidance in mining and tunneling„ the. Tp-0 is the :nvusy standard. Here s a fro reasons why: Super -bright beam: TP-L4's patented Green Beam, ri' brill{ test, most �Asible idser beam. tes easily seen even in bright sunlight Easy -to -see display: The large, baddit LCD is sloped so ,rou can eas.liv see the panel without climbing into it:e manhole or trench. Safer, faster, better. Functional accessibility anywhere T E e RC-200 n r ntr' puts ail Ot the- fPrt(1Q . r t n ertips a,&,, trier' rju're at the Idser or -r io 66�f away. Tough and reliable: A Lt' lit'y Iracj--r has to mort the de ,mds of P, ... _, site cor Nl' ins, :end Topcon's TP-LAI is #rr the o.gfiesi. is aH c -aluminum hc,using is 4 I":rrf i) iM4� p out rnfoisture, even "hen submerged It cknnicnew.,ri in the harshest environments. en corn", ned with featurt , Bil e? 5martl ine��, auto -alignment, the &orld's rr o f accurate grade .: -,anism, p-mwr options ihdt ,ket,p y'c:ili wor°i; ng wh-en other iasers haw given tip Tit°s no ivondi:°r ioxcon has set the standard, There are four TP-L4 modek to rho; -se frorn, vArh r^earts five ways to g-t there from i.ere whin your budget. The best way to get started is to call your Topcon de,:ler today. TP-L4 SERIES I T4PCQ11 The TP-L4 Series: It's about increased productivity. It`s about increased control. It`s about increased value. It's about time. and its only from Topton... Why green? Precision Grade Setting for Peak Production - Vii'clmkYs rrrusi accurate levetngand grade system Star^e 4 id r.rr;,ykr. c Peiironic encodYr supeemr at <In,N,fiFade Redl,r,r es rp4va7fl World's Only 3-way Beam (T-1_40J/A` D irrpii,lt .:t <,P rfc l +, 5 i p tl. • rstar t, vs°lNe p'iumb reference • No rnor-_iturn5 lei, hassles Qwk. 2rd af-curate micro-tunnehrig setups Widest Array of Power Management Choices ci rr edble battery pd(k means no cdbltS to uil'rail tareak .orven en' i'; hour quick charge I lvdk; con =.Pion pc w fn the laser and recharges the batte-,, at the same time Ali ;lino 1• ler',y pack option The Standard RC-200 Infrared Remote: complete laser control, without being in the hole: Smart Line auto -alignment laser "standby' to save battery prover lean klctde to preoseiy manage brightness. • Ai:to-Cer;tering • Grade Match for quick grade reference and eievewn matching Sarpit, You cacti see our Green Bearn anyNhere and under aoy conditions, Its t)-i-- i-xe visible carlsirucbcn laser ezrl In fact, Lhe TR+tG Gree=, 6eum is four times e&.& tis find in bright sunlight than C6-WeildOnal beams. So setup, grading and pipe instal- lation is fast and easy. Dow >E ttl a �•._.,lT. „°- .tom Visible Spedirma PG 61 East, dependable, durable, accurate, visible. 4 times more visible! Accessories The TR-1.4 — all the pipe laser, with all the Features, you'll ever need. 56955K Spatting Scope (green fitter) Rugged cast aluminul waterproof housing for tough "in-the-trenchconditions Stringline attachment Top loading battery pack to replace for qu ck alignment 4; batteries without disturbing the laser 56820K Spotting Scope (red filter) Smart Line automatic alimrint ! i P-L4GViAi - - F Nl Lod grade and line settings for undisturbed ciperatwn w 56935 Trivet Stand 3 Beam made matches o. beamgirt fore:t.veambient l l managemenC r ru Lefy'Right line col + ~ and automatic center:°' of range retur ml) rf 1"' 56095 Transit Tower .' Rubber bumper/stand Assembly pra.ects lens from falls X` !1 and enables one man to lower unr, into a trench or manhole - _ R:i .-.red I s provide - man ; m tdability and a tight 56833 Drop Manhole grip, e en ^ pAVic pipe Bracket Tivo grade entry methods Up,Dokvn !aser plummet to fit user preferences, plus eliminates troublesome plumb automatic 0% grade retum bob setups (TP-L4GV/AV) for quick setup changes 9210-1022 Tripod Large illuminated LCD display makes Adaptor Removable handle makes unit grade, line, battery, and beam mode easy to fit into tight im^^a is inlormation easy to see and use Other Accessories Dsgital level via pr'rmit� east f. rraugh leveling in the crass Drop op hianhde Mount axis right on the display Alkaline Battery Pack Grade Rods Tripods "Smart line" ("I-P-1-4tSV/AVIG) Standard Package (TP•L4GV shown) Acct� crate P%xiuction by hfaking Setup and Align- �t� y� Everyl rng you net t to gel the fob done, right out rnen4 Alirtnruwtis. Pateni Bunn ng terhr o obi (D of the case. o rr, Yin s" ;mot : C, B" ll 12' leg sets allnsv5 the• rt��ifrJstny s onty fa4, accurate ne person, rr automligrimc nt feature: the Sri Line. •.' "` -'g °" �" Carry Case rrcett�i�- • Single Panted Roof For secorxi clay setups, enter t:;re cnaect grade 6• to 18- Adjustable Targets in the laser and pDVion the target at the end of -Remote Control RC 2txi yesterday's last section of pipe. Press the Smart Lire Wad Battery 9T-38Q ,. button (on the laser or remote) and the laser autumatically funds the target center, letting your Battery o Charger Cr ble PC- • 12Vdc Power Cable PC-t7 crew start another daWs production vtiithout delay - Instruction Manual ` "`• r PG 62 A The Leader in Positioning Technology.- Specifications I npcon ciffm. positioning products that deliver TP-L4GV TP44AV TP-L4ri TP-L48G PAU uripdralieied site -wide performance and integration- Laser Source 532 nm Diode 633 nm Diode 532 rim Diode 532 nm Diode 633 nm Diode TWon's history of te:ri ri olcgK 31 advances and our Beam Color Green Red Green CKM Red reputation for superior rp4abiVio,, ineans there's no Smart Line Auto Alignment other company pmtinned to prolode you with a Yes Yes yes No No better 'Total Positioning Solution' Auto Line Centering Yes Yes Yes yes yes From survey to inspection Topcon, through our Auto Grade Zeroing Yes yes yes yes Yes Plumb Reference Yes Yes yes yes Yes 170+ dealers throughout North and South America. plumb Reference Type Laser Diode Laser Diode LED LED LED prov,de-the inm-r�iative technology that gives surveyors, crol engineers, contractors, equipment Smart Lim Opazthg Range owners, and operators the competitive eJgc- by 5W It (150 rn) 500 ft (150 M) W ft (150 rn) NJA N/A addressing such cmcal issues as inueasaig profits, Grade Range-15%-40% -15%-40% -15%-40% -15%-40% -15%-4046 quality crafNnariship, impro%nng productivity, toftf- Line Range � 15-1,* ±15% t15% ±15% ±15% ing operatri,? costs, and enhancing job site safety Horizontal Accuracy ±io' t11Y ±10' ±10' ±IT Battery Life 45hrs/32hrs 70hr5148* 45tn32hrs 45hrV32hrs 70Irs(48hrs F0 integration field -to -finish: TVs the goal of Tirpcon. When r'S time for you to step Up to Standard Warranty 2 Years 2 Years 2 Years I Year I Year the nett iev(4, ifs timew tuna to Top(on. Housing Construction Cast Aluminum The Leader in Customer Waterproof Depth At least 16.5 ft (5 m) for 24 hours Satisfaction... Operating Temperature -4r - 12 2*F (2CC - 50*C) o erisurf! mat,,our TolXcir, iz,,ei r-ndintairts peak perloonan(e, Voi ir 1rul Topton dealer offers factory RC-200 Remote Control trains} and ieftifii, d serwe techritictans. If senAce operating Range from TP-1.4 Front 660ft (200m) isn't available in your area, our factory offers a repair Operating Range from above panel a2ft (25m) and return policy second to none. Battery Life Approximately 8 Months Offices Worldwide TOPCON CORPORATION There's a TP-1-4 just right for you..,. 1Lkkt4VL - !*VC 174-8%C IW-91 No matter what type of pipe work you do, Topcon has a TPL4 dust right for your -1F1_ 3-5w"214 �,-)b and your tmdget- Topm E-We Po9ficabW &W. TP-L4GV , Cireenf!eam4t w1h laser plumb TP-L4AV - ked beam with laser plumb F 2CL 0k) 4- WA5 - TP-L4G .',,eenR-eam19wthLED plumb iopm E-pwA- Seta OW- TP-L4BG - Econorny GreenBeamlskh LED pMurnb &A AL rer 1, �—qArq, 4mt &J" Emy" TP-L4B F-Ici.rom.-redbeam v,4h LED rAur-11 Jff,*XW" W'16. (ANA Tel Other Topcon laser solutions: General Construction Lasers: The Rl.-H3C Series of infra -red cors:judon lasers is a Topcon best value, with a host of World -Leading teatures ean unb eatable prices. They're the perfectTopcon general constrixtion laser fo?,irry rw It's time. ynow Q;-�*; choose from: RL-H3A ally automatic, self4evelrg with 1,15V (350m) operating radius ..-..3C -,,11yautornat4 self le cling vAth 500'(150m) operating radius Topcon Positioning Systems, Inc. RL-H3CL ftyP automatic, self -leveling with long-range 820' (250m) radius 7400 Nationdf Drive RL-H3C5 fully automatic, seq-leveling, slope match capabW with 500' (150m) Livermore, CA 94550 ope,4tngradius wwwtopconpositioning.corn Your local Authorized Topcon dealer is: SpaNagou IM dime NOM Raft 020067opcmlccrporatxARoightsreserwd. PN 70165027 Rev. G Printed in USA 06/06 PG 63 g.:- 32 Avc e-r Bor',n5 fi-27-1/ Gro,a,-Y 1 Qr &vi-si d e o�- 42" Pipe, A-c,e e te,4 wl (7 hs-r diloher>e r��� 111o� c�t,cn��y 1kc- 7' Cand1honst. Submittal Lint,WFow�IerCo. Transmittal „ 140 'F P"pl-S Or S`w6- P"Pes. Submittal No. S028 Gertend (.axuruc,tors Date: 11 /23/2011 Lake Ave S/Rainier Ave S Storm System Project To: Daniel Carey From: Shannon Phipps Co.: City of Renton Co.: James W. Fowler Co. WE ARE SENDING: ® Attached ❑ Enclosed ❑ Under Separate Cover Via: THE FOLLOWING ITEMS: ® Submittals ❑ Product/Data ❑ Samples ❑ Plans ❑ Shop Drawings ❑ Copies ❑ Specifications ❑ Contract ❑ Other: TRANSMITTED AS CHECKED BELOW: ® For Approval ® For Review and Comment ❑ For Your Use ❑ Per Your Request ❑ Other: Copies Spec Section Description of Product / Data Subcontractor / Supplier 1 1-07-20.2 S028 - BI 32 Grout for casing pipe James W. Fowler Co. REMARKS: NO EXCEPTION TAKEN/MMAKE CORRECTIONS N l REJECTED p NOTED D C REVISE AND RESUBMIT 0 SEE ATTACHED COMMENT SHEET DATED a .Q CHECKING IS ONLY FOR GENERAL CONFORMANCE WITH THE DESIGN CON- CEPT OF THE PROJECT AND GENERAL COMPLIANCE WITH THE INFORMATION GIVEN IN THE CONTRACT DOCUMENTS. ANY ACTION SHOWN IS SUBJECT TO THE REQUIREMENTS OF THE PLANS AND SPECIFICATIONS, CONTRACTOR IS RESPONSIBLE FOR: DIMENSIONS WHICH SHALL BE CONFIRMED AND CORREL. ATED AT THE JOB SITE; FABRICATION PROCESSES AND TECHNIQUES OF CON- STRUCTION, COORDINATION OF HIS WORK WITH THAT OF ALL OTHER TRADES AND THE SATISFACTORY PERFORMANCE 'OF'HIS /WORK. GATE A RM7. E471 p { 7,; Ken Faught, LLC Consulting Services Grouting, Drilled Shaft Mitigation & Vibration Monitoring (425) 299-5344 klfaught@earth link. net CL.J.001.038 November 22, 2011 Shannon Phipps Project Manager James W. Fowler Company 12775 Westview Drive Dallas, OR 97338 Re: Annulus grouting of Lake Ave S. / Rainier Ave S. Storm System Project — 42 inch casing Gentlemen I reviewed the plans and specs you provided and prepared the following grouting procedure. I do not have equipment cut sheets or material supplier lists, so this is not a complete submittal package. You may include it in your submittal package along with the other required information. The specification requires the use of Type V cement. Recently there has been some difficulty in purchasing this type of cement in the Seattle Area. If it is not available, you may achieve high sulfate resistance by substituting type 1/11 Portland cement with 30% replacement with Type F flyash. Purpose of grouting: Filling voids outside the casing pipe Materials: Typed-Partiarrd Cement -conforming to A&-TM--C150. Sodium Bentonite conforming with API 13 A Potable water. Equipment: High shear colloidal mixer —Chem Grout CG-600 or equivalent. see attached. Grout hoses and fittings rated for 300 psi working pressure Gages fitted with gage isolator and having 2 or 4 inch face and +/- 4% rating Volume Estimate: The volume for contact grouting of a liner is based on the assumption of filling the overcut annulus around the pipe. In many cases, the annulus collapses on the pipe and the total grout take is less than the theoretical volume. In some cases there is obvious settlement above the casing which indicates over excavation of soil and large over break around it. Some judgment is needed to determine if the over break is significant. For the purpose of this estimate, I do not have any information to confirm the presence of large voids, however you did say that there were obstructions in the fill. • 5529 Silvana Terrace Road • Stanwod, WA 98292 • Page 1 Ken Faught, LLC Consulting Services Voids often accompany delays and during the pipe driving. I used a low estimate of 14.5 gallons per foot of casing which is enough grout to form a continuous 2 inch thick ring around the pipe. If you inject 600 gallons of grout in a single port without return from an adjacent port, you may be losing the grout into a gravel layer or unrelated void and should stop injection. You may estimate your cement requirements from the 14.5 gallons per foot number. In the case of the 116 ft. run, you would need 14.5 X 116 = 1,680 gallons or 25 batches of grout. Grouting procedure: It is my understanding the site has been dewatered prior to installation of the casing. Accordingly there will not be any special procedure for opening the grout holes. If a low volume of water is found to enter thru the grout holes under low head, thread a nipple with a ball valve attached into the hole and close the ball valve to control the water. If no water is found, thread the nipple and ball vale into the hole and leave the ball valve open. Thread a 1" X 1.5" reducing bushing into the ball valve and thread a 1" tee fitting into the bushing. Thread a reducing bushing into one side of the tee fitting and install the pressure gage on that bushing. Thread a 1" cam lock coupling on the other side of the tee fitting. Set up the grout mixing station at a suitable location near the end of the casing. Provide a Saunders valve and grout return line on the output line from the pump. Provide a pressure gage and a ball valve on the line downstream from the Saunders valve. When grouting, always close the ball valve downstream from the pressure gage and open the Saunders valve full open before starting the pump. After the pump is started, partially close the Saunders valve until the pressure reading is correct, then open the grout line valve. Pull a hose into the casing to the most distant port and start the grout pump. Allow a few minutes for grout to reach the end of the hose, then stop the pump. Insert the grout hose into the connection and check to make sure the ball valve at the connection is open. Start the pump and monitor the pressure at the connection. Watch for grout return from adjacent injection ports. Continue grout injection until refusal to take grout occurs or until grout returns from an adjacent port. Refusal to take grout is defined as a flow rate of half a gallon per minute for 5 minutes at the maximum grouting pressure or return from an adjacent port. (If grout returns from an adjacent port and the flow rate and/or pressure indicates the port is still taking grout freely, continue injection until the grout flow rate decreases). When grout returns from an adjacent port, close the valve on that port. When grouting is complete at any port, close the valve and disconnect the hose. Move to the next port and continue grouting. Even if grout has returned from a port, connect to that port and attempt to inject grout. • 5529 Silvana Terrace Road • Stanwod, WA 98292 • Page 2 Ken Faught, LLC Consulting Services Grout Mix: The grout mix uses Portland Cement, Bentonite Slurry and water. The bentonite slurry should be mixed first and cement added to the slurry. Table 1 Cement/Bentonite Grout Water 50 gal 432 Ibs 6.9 cf Cement 4 bags 376 Ibs 1.9 cf Bentonite 25 Ibs 25 Ibs 0.15 cf 834 Ibs 9.0 cf Density = 92.7 Ibs / cf The amount of bentonite may be adjusted in the field due to temperature, type of bentonite, water hardness or other factors. If Type V cement is not available you may use Type 1/II cement and fly ash to achieve sulfate resistance in the grout. Typically I use 25 to 30% replacement with fly ash for sulfate resistance. In this case, batching with 30% replacement allows you to batch without complications. Tabel 1a Cement/flyash/bentonite grout Water 50 gal 432 Ibs 6.9 cf Cement 3 bags 282 Ibs 1.43 cf Flyash 1.5 bags 112.5 Ibs 0.72 cf Bentonite 25 Ibs 25 Ibs 0.15 cf 837 Ibs 9.0 cf Density = 93.1 Ibs / cf Quality Control and Quality Assurance The required quality control tests are the mud balance test and marsh cone test. Mud balance should be between 92.2 and 93.0 Ibs per cubic foot (for cement/bentonite) For the cement/flyash/bentonite, the density should be between 92.7 and 93.6 Ibs/cf. Flow time should be between 40 and 60 seconds. If the first batch of the day is out of spec with the flow cone time, adjust the bentonite by increasing or decreasing by 50%. Continue testing and adjusting until the flow time is in the range. • 5529 Silvana Terrace Road • Stanwod, WA 98292 • Page 3 Ken Faught, LLC Consulting Services Take a set of 2 inch cube molds from the second batch and every 600 gallons afterward. If the cube molds are not available, 4 inch cylinder molds are OK. Pressure regulation The grouting pressure needs to be held at low pressure to prevent excessive grout take and/or damage to the pipe. The pipe can sustain relatively high pressure if the grout completely surrounds it. If the grout pressure is applied on only one side of the pipe, buckling can occur at low pressure. A very safe pressure is 1 psi per foot of cover, a commonly used pressure limit is 2 psi per foot of cover and in no case should the pressure exceed 20 psi. Very Truly Yours Ken Faugh LLC Consulting Services enneth L. Faught Principal Geologist • 5529 Silvana Terrace Road • Stanwod, WA 98292 0 Page 4 BENTONITE PUMP AND MIXER Model # MT750A-30EH Serial # WA9610- MICROTUNNELIN(; INC BOULDER, COLORADO, USA 303-444-2650 Fax 303-444-0889 1 2 3 13 4 5 6 7 8 9 10 11 12 1 750 GALLON MIXING TANK 2 ACCESS COVER, TOP OF TANK 3 VALVE, MIXING TANK SHUT-OFF TO CENTRIFUGAL PUMP 4 VALVE, FOR EXTERNAL PUMPING, SLURRY TANKS 5 VALVE, CENTRIFUGAL PUMP TO MIXING TANK AND MUD GUNS, SEE ITEM 31 6 CENTRIFUGAL PUMP 4" X 3", 1 7/8" PEDESTAL, I I" IMPELLER 7 VALVE, WATER SOURCE TO VENTURI MIXER 8 VALVE, VENTURI MIXER FEED SHUT-OFF 9 MOTOR, CENTRIFUGAL PUMP 15KW @ 380 VAC, 3 PHASE, 50 CYCLE 10 VALVE, VENTURI MIXER SUCTION SHUT-OFF 11 SIPHON ADJUSTORS, INSIDE VENTURI MIXER, 3 EACH 12 VENTURI MIXER 13 PLATFORM AND STEPS TO ACCESS COVER MICROTUNNELING� INC BOULDER, COLORADO, USA 303-444-2650 Fax 303-444-0889 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 FILTER, HYDRAULIC POWER PACK MOTOR, HYDRAULIC POWER PACK, 7.5KW @ 380VAC, 3 PHASE, 50 CYCLE RESERVOIR, HYDRAULIC POWER PACK, 40 GALLON HYDRAULIC SWITCH, FOR 0-15 GPM OR 0-30 GPM VALVE, METERING FOR PLUNGER PUMP SPEED FLOW GAUGE, IN GALLONS PER MINUTE CONNECTOR DISCONNECT, CORD SET MOTOR, HYDRAULIC 2-SPEED FOR 0-15 GPM OR 0-30 GPM PUMP, PLUNGER 0-30 GPM @ 200 PSI OR 0-15 GPM @ 500 PSI ELECTRICAL PANEL, SYSTEM CONTROLS, 380 VAC RECIRCULATION LINE, (BY-PASS LINE) VALVE, ANTI -FREEZE CONTAINER VALVE, MIXING TANK SHUT-OFF TO PLUNGER PUMP CONTAINER, ANTI -FREEZE VALVE, RECIRCULATION LINE SHUT-OFF GAUGE, SYSTEM PRESSURE VALVE, MIXER TANK FILL MUD GUNS, LOCATED INSIDE MIXER TANK, SEE VALVE 5 MICROTUNNELINGy INC BOULDER, COLORADO, USA 303-444-2650 Fax 303-444-0889 1 750 GALLON MIXING TANK 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 INDEX ACCESS COVER, TOP OF TANK VALVE, MIXING TANK SHUT-OFF TO CENTRIFUGAL PUMP VALVE, FOR EXTERNAL PUMPING, SLURRY TANKS VALVE, CENTRIFUGAL PUMP TO MIXING TANK AND MUD GUNS, SEE ITEM 31 CENTRIFUGAL PUMP 4" X 3", 1 7/8" PEDESTAL, I I" IMPELLER VALVE, WATER SOURCE TO VENTURI MIXER VALVE, VENTURI MIXER FEED SHUT-OFF MOTOR, CENTRIFUGAL PUMP 15KW @ 380 VAC, 3 PHASE, 50 CYCLE VALVE, VENTURI MIXER SUCTION SHUT-OFF SIPHON ADJUSTERS, INSIDE VENTURI MIXER, 3 EACH VENTURI MIXER PLATFORM AND STEPS TO ACCESS COVER FILTER, HYDRAULIC POWER PACK MOTOR, HYDRAULIC POWER PACK, 7.5KW @ 380VAC, 3 PHASE, 50 CYCLE RESERVOIR, HYDRAULIC POWER PACK, 40 GALLON HYDRAULIC SWITCH, FOR 0-15 GPM OR 0-30 GPM VALVE, METERING FOR PLUNGER PUMP SPEED FLOW GAUGE, IN GALLONS PER MINUTE CONNECTOR DISCONNECT, CORD SET MOTOR, HYDRAULIC 2-SPEED FOR 0-15 GPM OR 0-30 GPM PUMP, PLUNGER 0-30 GPM @ 200 PSI OR 0-15 GPM @ 500 PSI ELECTRICAL PANEL, SYSTEM CONTROLS, 380 VAC RECIRCULATION LINE, (BY-PASS LINE) VALVE, ANTI -FREEZE CONTAINER VALVE, MIXING TANK SHUT-OFF TO PLUNGER PUMP CONTAINER, ANTI -FREEZE VALVE, RECIRCULATION LINE SHUT-OFF GAUGE, SYSTEM PRESSURE VALVE, MIXER TANK FILL MUD GUNS, LOCATED INSIDE MIXER TANK, SEE VALVE 5 MICROTUNNELING, INC BOULDER, COLORADO, USA 303-444- 2650 Fax 303-444-0889 BENTONITE PUMP AND MIXER MIXING Mixing starts with the introduction of water via valve #7 or #30. It should be noted that water with a pH of 8.5 will yield best when mixed with sodium bentonite. Mixing with the introduction of water through valve #7 => Valve #7 open => Valve #8 and #10 closed => Introduce fresh water into valve #7. NOTE: Insure water is at a minimum pressure of 45psi (approx. 3 bar). to generate enough vacuum and mixing action. => Turn water source on, maintain pressure. => Slowly open valve #10. Position of valve will need to be determined as site conditions warrant. => A vacuum will be felt from within the venturi mixer, near the siphon adjusters. There are three siphon adjusters each with different size holes. The smaller the hole the slower the bentonite will be drawn, the best pre -mixing will be accomplished with the smallest size hole. Three sizes are included to account for varying site conditions. => Bentonite mixture should be determined prior to mixing (gallons vs. amount of bentonite, for a 1% through 6% solution, approximately). Add bentonite by lifting bag and dropping into venturi mixer. NOTE: Within the top portion of the venturi mixer a bag cutter will pierce the bottom of bag and allow the bentonite to fall to the siphon adjusters and into the pre -mixing section. => Close valve #10 once the pre -determined amount of bentonite has been added. Keep the water ON to fill tank to desired level. CAUTION: Failure to keep venturi mixer dry will cause it to "plug". If in the event this happens valve #10 can be removed via three quick disconnect clamps, the interior can then be cleaned. => Close valve #7 and #8. => The bentonite is now pre -mixed and needs to be mixed or blended thoroughly. Open valve #3, #5. Valve #4 keep closed. Connect power cord to connector body #20. Energize power cable. => Turn ON the "Pump Switch" on the electrical panel #23. => Pre -mixed bentonite will be drawn through a 4" x 3" Pump and then forced through the "Mud Guns" located within the 750 Gallon Mixer. This combined action will create the necessary "shear" to completely blend the bentonite within minutes. The type bentonite used the pH of the water used and the rate of the initial pre -mix will determine the blend time. NOTE: Once mixed the blending operation should be stopped. Turn OFF the "Pump Switch" on the electrical panel #23. MICROTUNNELIN(y INC BOULDER, COLORADO, USA 303-444-2650 Fax 303-444-0889 Mixing with the introduction of water through Valve #28 => Open Valve #30. => Fill with water the 750 gallon tank to the desired level. zz> Open valve #3, #5, #8. Close valve #4, #7, #10. => Connect power cord to connector body #20. Energize power cable. => Turn ON the "Pump Switch" on the electrical panel #23. => Slowly open valve #10. A vacuum will be felt from within the venturi mixer, near the siphon adjusters. There are three siphon adjusters each with different size holes. The smaller the hole the slower the bentonite will be drawn, the best pre -mixing will be accomplished with the smallest size hole. Three sizes are included to account for varying site conditions. => Increased vacuum can be accomplished by closing Valve #5 a small amount. Water pressure should be in the order of 45 psi (3 bar). to generate enough vacuum and mixing action. => Bentonite mixture should be determined prior to mixing (gallons vs. amount of bentonite, for a 1% through 6% solution, approximately). =:> Add bentonite by lifting bag and dropping into venturi mixer. NOTE: Within the top portion of the venturi mixer a bag cutter will pierce the bottom of bag and allow the bentonite to fall to the siphon adjusters and into the pre -mixing section. => Close valve #10 once the pre -determined amount of bentonite has been added. Keep the centrifugal pump ON until valve #10 is closed. =:> CAUTION: Failure to keep venturi mixer dry will cause it to "plug". If in the event this happens valve #10 can be removed via three quick disconnect clamps, the interior can then be cleaned. => Open fully Valve #5. => Close Valve #8. => The bentonite is now pre -mixed and partially blended. It needs to be mixed or blended completely. => Pre -mixed bentonite will be drawn through a 4" x 3" Pump and then forced through the "Mud Guns" located within the 750 Gallon Mixer. This combined action will create the necessary "shear" to completely blend the bentonite within minutes. The type bentonite used the PH of the water used and the rate of the initial pre -mix will determine the blend time. NOTE: Once mixed the blending operation should be stopped. Turn OFF the "Pump Switch" on the electrical panel #23. Transferring bentonite through Valve #4, To Slurry Tanks => Open Valves #3, #4. Close Valves #5, #7, #8, #10. � Hookup hose to valve #4 and secure far end to desired fill area. => Connect power cord to connector body #20. Energize power cable. =:> Turn ON the "Pump Switch" on the electrical panel #23. => When tank is empty or desired amount of bentonite has been discharged, Turn OFF "Pump Switch" on the electrical panel #23. MICROTUNNELING� INC BOULDER, COLORADO, USA 303-444-2650 Fax 303-444-0889 Plunger Pump General System Information • Bentonite delivery is accomplished by a 30 GPM rated plunger pump. A two speed hydraulic motor powering the pump delivers 0-15 GPM at 200 psi or 0-30 GPM at 500 psi. The Plunger pump has a rating of 3500 psi continuous working pressure but at a higher kW rating than is installed on this pump. It provides a positive displacement delivery of bentonite lubrication. Its relief valve is set at 200 psi and for normal system delivery should be adequate. For higher than the 200 psi setting re -adjusting the relief valve is required, located in the lower section of the by-pass line #24. A by-pass line enables continuous pumping of the plunger pump discharging into the mixing tank. A pressure gauge records system pressure while a flow gauge advises the GPM flow rate. • Pump and mixer may also be used as a test pump and can pressurize lines to 500 psi. • A anti -freeze provision has been incorporated to prevent the problems associated with extreme cold weather. • A load make and break power cable connector provides an electrical disconnect means while serving as a power cable. • Three lifting points are only for use when the mixing tank is empty. • The Hydraulic power pack has a 40 gallon capacity tank and uses a ISO 32 hydraulic oil. Temperature extremes either too hot or cold will require re-examination of oil types. • A switch close to the flow gauge will change the hydraulic motor on the plunger pump from slow to high speed, causing flow rates from 0-15 and 0-30 GPM. Plunger Pump Delivery • Open valve #26, #28, Close valve #25. • Connect power cord to connector body #20. Energize power cable. • Close plunger pump system delivery valve (not provided). • Turn ON the "Hydraulic Pump Switch" on the electrical panel #23. • Adjust valve #17 for either high (0-30 GPM) or low (0-15 GPM) system flows. • Adjust needle Valve #18 to throttle pump speed. Clockwise to lower • Bentonite will by-pass, slowly open system delivery valve then close Valve #28. delivery pressure will build to adjusted limits. • Blocked lines or a closed system delivery valve will cause pressure to build. • During pipe change overs open Valve #28 to place system to by-pass and close system delivery valve. CAUTION ♦ Hydraulic filter should be changed every 100 hours of operation or once per month. ♦ Hydraulic oil to be replaced each 300 hours of operation or 180 days. ♦ Hoses need to be checked for leakage or visible damage each day. ♦ All electric power and hydraulic pressure must be off prior to any work being undertaken. ♦ Plunger Pump must not be allowed to run dry or damage to the pump will occur. MICROTUNNELIN(; INC BOULDER, COLORADO, USA 303-444-2650 Fax 303-444-0889 GROUT MIXING AND DELIVERY ► WARNING -------- - - - - --- -- - - - - THIS MIXER WAS DESIGNED TO MIX AND DELIVER BENTONITE TO PIPE JACKING AND MICROTUNNELING PROJECTS. GROUT MAY BE MIXED BUT EXTRA CAUTION NEEDS TO BE EXERCISED. THE SUPPLIERS OF THE SYSTEM COMPONENTS HAVE ASSURED US THAT GROUT MIXING AND DELIVERY SHOULD NOT CREATE ANY PROBLEMS IF DONE PROPERLY WITH THE SUPPLIED COMPONENTS. BASIC PROCEDURES FOR MIXING AND DELIVERY OF BENTONITE ARE THE SAME WITH CERTAIN ADDED STEPS. SINCE OPERATION AND MAINTENANCE SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL IT IS IMPORTANT THEY BE FAMILIAR WITH THE MIXER AND ITS OPERATION. ALL CONCERNED NEED TO CONTRIBUTE TOWARDS GOOD COMMON SENSE PROCEDURES DURING AND AFTER GROUT MIXING. BELOW ARE SOME POINTS TO CONSIDER: 1. CLEAN-UP WHEN FINISHED IS VERY IMPORTANT. 2. GROUT SETTING -UP INSIDE THE MIXER AND ITS COMPONENTS CANNOT BE ALLOWED TO HAPPEN. CONTINUOS BATCH MIXING WITHOUT CLEANING COULD ALLOW THE GROUT TO SET UP. 3. A LOW SLUMP (THICK) GROUT MIX WILL PROBABLY HAVE MORE PROB- LEMS THAN A THINNER MIX. 4. PLENTY OF WATER FOR FLUSHING OUT THE COMPONENTS IS NEEDED. 5. MAINTENANCE PERSONNEL AND THEIR TOOLS NEED TO BE PRESENT IN THE EVENT A COMPONENT NEEDS DISASSEMBLY AND CLEANING. 6. PLUNGER PUMP AND CENTRIFUGAL PUMP SEAL KITS SHOULD BE ON HAND PRIOR TO GROUT MIXING. IF PUMPS LEAK AFTER THE GROUTING OPERA - TIN THEN THE SEALS NEED TO BE CLEANED OR REPLACED. 7 GROUT MIXED TOO THICK CAN CAUSE THE CENTRIFUGAL PUMP TO OVER- LOAD. 8. THE USE OF A RETARDING AGENT FOR THE GROUT IS RECOMMENDED GROUT MIXING EQUIPMENT REQUIRES EXTRA WORK TO KEEP IT OPERATIONAL THIS MIXER IS NO DIFFERENT, PLAN AHEAD! MICROTUNNELING� INC BOULDER, COLORADO, USA 303-444-2650 Fax 303-444-0889