Concrete Protective Liners (CPL)
Sample Specifications

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1.0 General Conditions

1.1 Scope - This specification describes the fabrication and installation of double walled thermoplastic sheet liners for concrete protection.

1.2 Workmanship - All work shall be performed in strict accordance with these specifications and the manufacturer's current printed instructions. Work shall be performed by skilled technicians in a safe and professional manner.

2.0 Fabrication

2.1 Fabricator must be certified in the fabrication of SureGrip™ concrete protective liners (CPL) and regularly engage in the installation of lined pre-cast large diameter manholes and structures.

2.2 Fabricator shall have supplied and installed at least five double contained SureGrip™ CPL systems. Fabricator shall furnish evidence of a least five years of continuous experience related to CPL fabrication and installation.

2.3 Fabricator must possess construction site extrusion welding capabilities for final connections of sections and penetrations in the field.

3.0 Fabrication Procedures

3.1 All fabrication of HDPE dual contained SureGrip™ cylinder sections must be completed before shipment to concrete pre-caster. This does not include penetrations, sections or caps.

3.2 All SureGrip™ vertical welds made prior to pre-casting must be butt fused on automated equipment designed specifically for welding thermoplastic sheets. This does not include the on-site welding of SureGrip™ penetrations, sections or caps.

3.3 Computer aided design drawings shall be submitted prior to construction for approval from the engineer of record. Drawings must give clear representation of the leak detection system.

4.0 Testing and QA/QC

4.1 All fabricated CPL components shall be tested upon completion of shop fabrication prior to shipment to the pre-caster. Non destructive tests of welds shall be performed utilizing "spark tape". This procedure involves an electric current from a spark testing gun which will identify holes or penetrations in the weld. If defects are found, the weld shall be ground out and the area will be re-welded and tested again. Where applicable, a vacuum test shall be performed on the annular space to insure a leak free double contained system. Using the leak detection pipe as a test port, a vacuum of 7" Hg shall be put on the annulus for 15 minutes without loosing vacuum. No positive pressure shall be placed on the annulus in any situation without the written consent of the fabricator.

4.2 All materials used in the fabrication of the CPL shall be compatible. The fabricator shall furnish material certifications from the manufacturer of the CPL.

5.0 Materials

5.1 Sheet liners are to be high performance thermoplastic sheets with anchoring studs that are extruded as a part of the sheet. No secondary manufacturing processes will be allowed for attaching the anchoring studs to the CPL. Mechanically attached systems and / or fabricated sheets will not be allowed.

5.2 the double contained CPL shall be High Density Polyethylene SureGrip™ as furnished by Plastic Fusion Fabricators, Inc., Huntsville, AL. Any other CPL shall be submitted to the engineer for approval at least thirty days prior to the bid date.

5.3 The properties of the material shall be as shown in the linked table.

5.4 The CPL for this project shall be a double walled, dual sealing material manufactured specifically for providing primary and secondary containment. The primary liner shall be fusion bonded to the secondary liner by the manufacturer of the CPL.

6.0 Pre-cast Concrete

6.1 All precuts concrete materials and manufacturing processes shall be in accordance with industry standards. See pre-cast concrete specifications.

SureGrip® Sheet Design Values
Note: DIN is the European equivalent to ASTM Standards.

Property

Testing Method

Unit

HDPE

PP-R

PVDF

Density DIN 53479 (ASTM D 792-86) g/cm3 0.945 0.898 1.78
MFI (Melt Flow Index)` DIN 53735 (ASTM D 1238-88) g/10 min. 0.7-1.0 (190/5) 0.5 (190/5) 3-5 (230-5)
Heat Reversion (Dimensional Stability) DIN16726 (ASTM D 1637-83) % <2 <2 <1
Yield Stress DIN 53455 (ASTM D638-89) N/mm² >=16 >=2,320 >=20 >=2,900 >=50 >=7,250
Elongation of Yield Test Bar (ASTM D638-89) % >=12 >=10 >=8
Elongation at Break v = 50mm / min (ASTM D638-89) % >=200 >=50 >=50
Fire Classification DIN 4102 / part 1 UL-94   B2
V2
B2
V2
B1
V-O
Electric Conductivity     10¹³ 10¹³ 10¹³
Resistance to Pull-Out SKZ test directives t/m² t/ft² 30
3
30
3
30
3
Maximum Working Temperature   ºC
°F
60
140
90
194
130
266

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