Polypropylene Installation Procedures
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SECTION I:  GENERAL SEQUENCE OF EVENTS
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1. See attached II "Installer Furnished Materials For Installation" and prepare materials necessary for lining installation.
2. Only unfold  the panels that are to be anchored or seamed together in one day.  See section VI, "Unfolding and Spreading Prefabriated Panels". 
3. After the panels are initially placed, remove as many wrinkles as practical.  If possible, allow the panels to "relax" by warming in the sun.  The edges to be bonded should be as smooth and free of wrinkles as attainable to ensure smooth and wrinkle-free field seams.
4. When panels are in position, commence field seaming operations.  See section IX, "Recommended Guidelines for Field Seaming Procedures Using WedgeWelders".
5. At the end of each day all unseamed edges should be anchored by sandbags.  If winds are expected, boards along the edges of the panels, with sandbags on top, should be used to anchor the liner, or a "wind row" of backfill material placed three-feet back from leading edge.  Other ballast materials, such as rolls of geotextile, may be used at the determination of the installer.
6. After field seaming is completed in a given area, and ONLY then, should liner edges in the anchor trench be buried.



NOTE:    Do not bury the liner edge in the anchor trench within 30 feet of an "incomplete" field seam.  This allows the seam area to be re-tensioned to remove wrinkles along the seam area.

7. To begin the field seaming, always start in the middle and work toward an open end.  This will minimize large wrinkles from becoming trapped - which will require cutting and patching.
    

SECTION II:  INSTALLER FURNISHED MATERIALS FOR INSTALLATION
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      Installer should supply the following for installation of prefabricated panels of AccuGeo PP Liners:

1. All field installation labor and official supervision, i.e., crew chief or foreman.
2. The means to move packaged, folded panels of liner to specific locations on site.  Panels will weigh up to 6,000 pounds.
3. Stakes and string or chalk lines (not lime) to define panel location and initial unfolding guidelines.
4. Canvas, burlap or polyethylene bags filled with sand, or soft dirt, to hold the  unseamed edges in place.  Quantity depends on wind present during installation;  figure one (1) bag per ten (10) feet of unanchored panel perimeter.  Note that continuous ballast must be provided along an unsecured edge for strong wind conditions.
5. Minimum of (2) hand rakes, or large paving rakes and (2) shovels.
6. One or more compacting rollers for smoothing out or compacting rough or badly gouged earth at the pit site.
7. Portable hot air gun, extension cords, and power source (See XII"Tool List For Field Seaming Crews").
8. Box or barrel of clean cotton rags.
9. Surveyor's tape measure.
10. Can of surveyor's spray paint.
11. All proper safety equipment and supplies.  The customer is responsible for all safety aspects of the installation.
12. All persons at the site should have smooth, protrusion-free shoe soles (no heels) tennis shoes or smooth, rubber-soled work shoes.
13. If field seaming will be performed, all required equipment listed on the attached XII "Tool List for Field Seaming Crews" should be provided.
14. All workmen should wear gloves so the hot liner will not blister their knuckles while spreading the panels.  This is particularly true during the summer months.
15. Each crew member should have a 1' x 2" grade stake (with pointed end cut off) or dowel.  These will be used to prevent damage to the panel when spreading and to protect the crew members hands.  The folded edge of the panel should be rolled around the stake in preparation for spreading the panel.

 

Preparations to be made the afternoon or evening before commencement of the lining operations.

1. All equipment, tools and supplies to be at the pond site and properly stored.
2. Soil sterilant should be applied when control of vegetation is needed.
3. The first day's panels to be in position.  Leave the panels packaged.  If hot sunlight is present, shade the panels using any opaque sheeting.  Leave a free-flowing air space between the opaque sheeting and the panels.
4. An anchor trench dug, if required, entirely around pond.  The soil should be spread out (raked back, flat, away from anchor trench) so panels can be unfolded on the top of the berm.
5. Stakes installed and/or lines measured and drawn indicating panel locations, reference lines, etc.
6. All pond dimensions checked to verify actual pond dimension are not greater than shown on the drawing.
7. Pond preparations for the covering of the liner:
   
   

   Pond surface raked smooth, rolled if necessary.  Free of all large, sharp rocks, or other sharp objects, and free of all vegetation and/or stubble. Soil sterilization shall be performed if required.  All penetrations, (pipes, etc.) covered or wrapped to protect liner from being cut, abraded or punctured during installation.  Where bonding of liner to concrete is required, the surface should be smooth, clean, dry and smooth finished.  All pipes, drains, fitting, etc., which are to be installed beneath the liner, should be in place and ready to be covered with the liner.

   
   
8. Distribute sandbags (about one every ten feet) along the perimeters of the area to be lined the next day.  DO NOT put them in the area where the panels will be unfolded, but immediately adjacent.
   
   

SECTION IV: FABRICATOR PACKAGING
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The PP lining is accordion folded (in both directions) to fit on the pallet.  Liner panels are wrapped with a protective cover of .010" PVC liner and adequately packed and loaded for shipment to prevent damage during transit.  Wooden pallets shall be free from mechanical obstructions such as nails, screws, or other fasteners, etc. that may damage lining. Any lining that is damaged during shipment, storage, or installation must be repaired by the Contractor before placement of the protective cover materials or backfill.



SECTION V: CONTRACTOR STORAGE
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The PP lining material should be stored at the job site in its' original unopened packaging to protect the material against damage.  When possible, PP liner material should be stored in dry areas offering protection from direct heat of the sun especially if the storage period is long.  Space should be allowed between each liner pallet for ease of identification and abrasion prevention.  Pallets of liner shall never be stacked.



SECTION VI: UNFOLDING AND SPREADING PREFABRICATED PANELS
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1. The Liner panel is marked on the outside covering indicating the panel identification letter or number.  (The panel markings are also on the material inside the packaging).
2. When ready to unfold the panels, remove the packaging carefully.  DO NOT USE A KNIFE AS DAMAGE TO LINER MAY OCCUR.  Before unfolding panels from the pallet, carefully inspect for protrusions and remove any protrusions which may cause damage.
3. Positioning the panel and unfolding it from the pallet is best handled with a large four-yard front-end loader or forklift.  The panel may weigh as much as 6000 pounds.
4. After the panel is unfolded, it is straightened out to the layout guidelines.
5. The panel is then spread into position.  Men are positioned at the edge of the panel as indicated by the Crew Chief.  The men are positioned approximately 15 feet apart, depending on the size of the panel and the terrain to be covered.  If required, men are positioned at the uphill end of the panel to keep it from sliding down the slope as it is unfolded.  If the edge to be gripped is subsequently to be bonded, then the panel edge is folded back about two (2) or three (3) feet creating  a fold.  The fold is gripped using the 1' X 2" grade stake or dowel wrapped in the material for pulling inside the panel rather than the edge itself.  This is to avoid stretching the edge where it is to be bonded.
6. As the panel is pulled out it is necessary to maintain air under the liner for buoyancy.  This can be accomplished in several ways.  One is to simply hold the edge and advance at a rate fast enough to create air under the liner as it is unfolded.  Another is to "fan" air under the liner.  This is done by raising and lowering the edge of the panel to create a wave like action across the liner as it is being spread.  This fanning action should be directed by the Technical Service Representative or Crew Chief.  Caution should be observed when spreading the panel under windy conditions. The panel should always be pulled into the wind to facilitate proper air flotation. Extreme care must be taken to prevent the liner from getting out of control and blowing away.
7. A slight lateral tension on the leading edge of the panel being spread should be maintained.  This lateral tension facilitates the spreading operations.

 

1. During unfolding-spreading operations it is necessary that the crew wear gloves, as these operations can be quite chafing to the knuckles.
2. During unfolding-spreading operations it is necessary that the crew work as a team.
3. If a gust of wind begins to pull the liner away from the crew and they are about to lose their footing, apply lateral tension in the leading edge and lower it to the ground. Attempt to restrain it further by placing one knee on the leading edge. If these efforts fail to restrain it, LET IT GO, DO NOT HOLD ONTO THE LINER, DON'T BE PULLED ALONG WITH THE WIND. 
4. Extreme caution should be exercised when walking on the PP liner material when wet.  The sheeting becomes very slippery.  It is often necessary to use a rope as an aid in going in or out of ponds.
   
   

SECTION VII: PATCHING INSTRUCTIONS FOR PP LINERS
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Patches must be made from the parent material (same gauge or thicker (PP) and be cut to allow a minimum of 3" overlap outside of the damaged area for bonding.  The patch is to be applied with a heat gun or hot air gun and must be rolled and/or burnished to ensure a complete seal.



SECTION VIII: FIELD SEAM TESTING METHODS FOR HEAT WELDS
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All field seams made to join liner panels or penetration details (such as pipe boots) shall be 100% both visually inspected for integrity and air lance tested using a pressure of 40 p.s.i..  Any areas found not to be properly bonded shall be identified by Q/C Inspection personnel for patching or other appropriate measures to correct the condition.  Any problematical areas found shall be visibly identified with a bright marker that will not interfere with repair process itself.  After repairs are made, every identified area must be re-inspected and approved by Q/C personnel before backfilling operations over the affected area are to occur.

Optional (existing job specifications may overrule):

Non-destructive coupon samples shall be taken at least twice each day for each seaming technician at the beginning and end of field seaming operations.  Non-destructive coupon samples shall have minimum measurements of 12" X 24" (lengthwise being parallel to the seam direction) and shall be identified as to the time of day, and the name of the seaming technician.  Testing shall be in the shear and peel directions.  Test methods and passing criteria shall be in accordance with ASTM D751 and D413 (NSF Modified).  The Installation Contractor shall draft an as built drawing of the liner system concurrently with the progression of work to be retained as a permanent record of the job.  This drawing shall include the identification and location of all installed panels.



SECTION IX: RECOMMENDED GUIDELINES FOR FIELD SEAMING PROCEDURES USING WEDGE WELDERS
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This guideline recommends that wedge welding and related Q/C procedures be decided upon by the installation contractor.  Any such intention should be with the knowledge and approval of the concerned Project Engineer and/or Owner.



SECTION X: INSTALLING PIPE BOOT PENETRATION DETAILS
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Whenever possible, avoid slitting liner panels for piping details until boot itself is ready for immediate installation.  Generally, it is best to let the lining material straddle a relatively small protrusion (for later detail work) provided that the object is first blunted (i.e. attached rag etc.) to avoid abrasion or other damage to the liner.  Premature cutting of a liner panel for a penetration detail can lead to serious damage to the liner in situations where winds and/or precipitation may occur and the liner is not well ballasted or otherwise protected.  Cuts made in liner for clearance over protrusions should always be made as small as possible to minimize possible patch work or wind damage etc.  Factory prepared pipe boots should fit snugly but not require excessive force to pull over a detail.  If a boot feels overly snug but workable, try applying either talc powder or using compressed air with a nozzle to float the boot sleeve over the pipe.  Boots should never be installed that require enough force to permanently stress or weaken them.  When properly installed, the pipe boot will lay flat against grade surrounding pipe without leaving pockets that may become stressed both during and after placement of backfill.  Pipe boot aprons shall be seamed to the parent liner at the interface surface using a heat gun. Proper leakproof sealing of boot details shall be verified by air lance or pick technique yielding no loose or curled edges.  The pipe boot sleeve shall be attached to the pipe using the clamping/sealing detail specified in job drawings or by engineer.



SECTION XI: TOOL LIST FOR FIELD SEAMING CREWS
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1. One (1) set size 10 cloth gloves.
2. Two (2) set knee pads.  (If desired)
3. Roll of tape to hold on knee pads.
4. Ten (10) cotton rags per hour (24# box normally is adequate).
5. One (1) whisk broom (or fox tail brush).
6. One (1) Stanley Knife.
7. One (1) red or yellow crayon for marking liner surface.
8. One (1) pair of scissors with rounded-off points.
9. One (1) 2" plastic or wood wallpaper seam roller per each field seaming crew.
   

SECTION XII: COVERING PP LINER
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1. Care must be taken by equipment operators to avoid damaging the PP liner.
2. Heavy equipment should operate on a minimum 3 foot roadway where the "haul road" is established in and out of the pond.
3. Always operate equipment on a minimum of 12 inches of covering.  Avoid sharp turns with equipment that could pinch and rupture the liner.
4. If damage does occur, DO NOT COVER IT UP.  Advise the foreman so repair can be made.
   

SECTION XIII: MISCELLANEOUS ATTACHMENTS
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