PVC Installation Procedures
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SECTION I:  GENERAL SEQUENCE OF EVENTS
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1. See attached "Check-Off List of Materials" 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 Prefabricated 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 VIII "Recommended Guidelines for field seaming procedures using solvent Adhesive".
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 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 should be buried.
   NOTE:    Do not bury the liner edge in the anchor trench within 30 feet of an  incomplete" field seam.  This is to allow 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.
8. An earthen cover should be placed over the lining in one lift.
    
    
    

SECTION II:  INSTALLER FURNISHED MATERIALS FOR INSTALLATION
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Installer should supply the listed materials for installation of prefabricated panels of AccuGeo Liner PVC 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 "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 "Tool List for Field Seaming Crews" should be provided.
14. All workmen should wear gloves so the hot liner will not blister the back of 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.
     
     
     

SECTION III: INSTALLER MAKE-READY LIST
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Preparations to be made the afternoon or evening before commencement of the lining operations.
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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:
   A.   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.
   B.   All penetrations, (pipes, etc.) covered or wrapped to protect liner from being cut, abraded or punctured during installation.
   C.   Where bonding of liner to concrete is required, the surface should be smooth, clean, dry and smooth finished.
   D.   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 PVC lining is accordion folded (in both directions) to fit on the pallet.  Liner panels are wrapped with a protective cover of sacrificial .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 PVC lining material should be stored at the job site in it's original unopened packaging to protect the material against damage.  When possible, PVC 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 facilitate the spreading operations.
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NOTES:

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, the following points are applicable:
   1. Apply lateral tension in the leading edge and lower it to the ground.
   2. 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 PVC 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: RECOMMENDED GUIDELINES FOR FIELD SEAMING PROCEDURES USING SOLVENT ADHESIVE
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Seaming

1. Temperatures for seaming must be as follows: 
    Minimum ambient temperature:50 degrees f.; Minimum liner temperature: 90-100  degrees f.; Minimum solvent adhesive temperature: 70-80 degrees f.
2. Before adhesive is applied, surfaces to be seamed must be free of dirt and foreign materials.  The presence of a few particles of sand or dirt is permissible in situations where it is unavoidable.  The acceptable limit is when the particles are totally encapsulated in the adhesive/seam and they do not connect to form a path for a leak.
3. Adhesion of one liner panel to another is accomplished by lapping the edges of panels a minimum of 3-inches (6-inches is more desirable).  The contact surfaces of the panels should be wiped clean to remove all dirt, dust or other foreign materials.  A clean cloth, foxtail or grout brush may be used.  If adverse conditions exist, such as mud, caked mud, or clay, remove by clean water wash.  Then dry before attempting to continue with seaming procedure.  A seaming board should be placed under the liner portion to be immediately seamed.  Adhesive can be applied by use of squeeze bottles or cans with brushes for the length of the seaming board.  Cans and brushes must be used cautiously with a lid slit barely large enough to accept the brush, otherwise the adhesive can lose its "solvent grab" through evaporation of volatiles or contamination.  Always keep the dispensing vessel sealed when not in immediate use.  The actual bonded area must be continuous, extend to the exposed edge of the seam be a nominal 2"-3" wide and have a minimum width of 1/2 inch.  Using too much PVC bonding solvent in a wide area could result in a poor quality seam.  With a typical 2 inch wood or plastic wallpaper seam roller, burnish the freshly joined areas by rolling perpendicular to the seam squeezing out excess adhesive and air pockets. 
4. "Fishmouths" can be folded over and bonded closed or slit, bonded down and patched per instructions given by the Technical Advisor.  Patches over "fishmouths" or other seam flaws should extend at least 2 inches past the flaw in question.  The rule on patching should be: "If there is questions as to whether or not to patch, then patch it"!

Repairs

Before making repairs, the contact surfaces of the lining shall be thoroughly cleaned to remove all dirt, dust, moisture, and other foreign materials.  When making repairs, a hot-air gun or other approved heating device shall be used to warm the lining when the ambient air temperature is below 50 F.  No lining repairs shall be made when the ambient air temperature is below 35 F.  A solvent adhesive supplied or approved by AccuLiner, Inc. shall be used in the repair work.  All lining repairs shall be made using patches of parent material with rounded corners.  Any area repaired shall be inspected and approved by the Contracting Officer before placement of any cover.
 
 
 

SECTION VIII: PATCHING INSTRUCTIONS FOR PVC LINERS
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Patches must be made from the parent material (same gauge or thicker PVC) and be cut to allow a minimum of 3" overlap outside of the damaged area for bonding.  The patch is to be applied with the same adhesive as used for liner seaming and must be rolled and/or burnished to ensure a complete seal.
 
 
 

SECTION IX: FIELD SEAM TESTING METHODS FOR SOLVENT ADHESIVE 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 or 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, adhesive used and the name of the seaming technician.  Coupon seams shall be cured for a minimum of 20 hours including at least 6 hours of direct sunlight exposure and the balance being at room temperature.  Testing shall be in the shear and peel directions.  Test methods and passing criteria shall be in accordance with NSF 54-1991.  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 X: 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 XI: 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 the same techniques as described in section VII. In any instance where an apron doesn't cover a open area, that area shall be patched in accordance to repair procedures mentioned in section "VII repairs". Proper leakproof sealing of boot details shall be verified by air lance or pick technique yielding no lose 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 XII: 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. Gallon can with handle for adhesive.  Plastic applicator bottles can be ordered from  AccuLiner, Inc.
6. One (1) whisk broom (or fox tail brush).
7. One (1) 1" X 10" X 1'4-16' long Douglas fir clear board, rounded off on both ends as well as all edges, with a rope tied to one end to be used as a seaming board.
8. One (1) Stanley Knife.
9. One (1) red or yellow crayon for marking liner surface.
10. One (1) pair of scissors with rounded-off points.
11. Safety glasses for each man on seaming crew for protection from solvent splash.
12. One (1) 2" plastic or wood wallpaper seam roller per each field seaming crew.
     
     
     

SECTION XIII: COVERING PVC LINER
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1. Care must be taken by equipment operators to avoid damaging the PVC 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. When covering the side slopes always push cover material up the slope from the bottom of the pond.  This will avoid stressing the liner.
5. If damaged does occur, DO NOT COVER IT UP.  Advise the foreman so repair can be made.
    
    
    

SECTION XIV: MISCELLANEOUS ATTACHMENTS
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