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INSTALLATION RECOMMENDATIONS

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Summary

1. Materials....................................................................................................................................................... 2 1.1. Roll layout....................................................................................................................................... 2 1.2. Standard packaging of the rolls ..................................................................................................... 2 1.3. Position of the Kraft paper.............................................................................................................. 2 1.4. Labelling of the rolls ....................................................................................................................... 3 1.5. Taking delivery of the rolls ............................................................................................................. 3 1.6. Unloading – temporary storage...................................................................................................... 3 1.7. Transfer of the rolls to the installation area.................................................................................... 3 1.8. Mandrels......................................................................................................................................... 4 1.9. Production certificates.................................................................................................................... 4

2. Preparation of the subgrade......................................................................................................................... 5 2.1. Surface aspect ............................................................................................................................... 5 2.2. Slopes ............................................................................................................................................ 5 2.3. Transition area at foot of a slope ................................................................................................... 5 2.4. Bearing capacity............................................................................................................................. 6 2.5. Hand over procedure ..................................................................................................................... 6

3. Installation .................................................................................................................................................... 7 3.1. Typical crew ................................................................................................................................... 7 3.2. Heavy equipment ........................................................................................................................... 7 3.3. Personal protection equipment ...................................................................................................... 7 3.4. Small equipment ............................................................................................................................ 8 3.5. Weather conditions ........................................................................................................................ 8 3.6. Laying technique and procedures.................................................................................................. 8 3.7. Overlap width ................................................................................................................................. 8 3.8. Transverse joints............................................................................................................................ 9

4. Anchoring – ballasting................................................................................................................................ 10 4.1. Effects of wind.............................................................................................................................. 10 4.2. Temporary ballasting.................................................................................................................... 10 4.3. Final ballasting ............................................................................................................................. 10

5. Laps............................................................................................................................................................ 12 5.1. Typical manual welding crew ....................................................................................................... 12 5.2. Equipment for manual welding..................................................................................................... 12 5.3. Weather conditions ...................................................................................................................... 12 5.4. Technical details .......................................................................................................................... 13 5.5. Protection of geotextile against flame damage............................................................................ 14

6. Construction details.................................................................................................................................... 15 6.1. Connection to structure ................................................................................................................ 15 6.2. Connection to water inlets and outlets ......................................................................................... 17

7. control......................................................................................................................................................... 18 7.1. Total control – statistical control................................................................................................... 18 7.2. Visual assessment ....................................................................................................................... 18 7.3. Compressed air pressure testing ................................................................................................. 18 7.4. Vacuum bell testing...................................................................................................................... 18 7.5. Echograph testing ........................................................................................................................ 19 7.6. Automatic continuous testing ....................................................................................................... 19 7.7. Destructive testing........................................................................................................................ 20 7.8. Repairs of bad quality welds and creases ................................................................................... 20

8. Protection ................................................................................................................................................... 21 8.1. Specific precautions ..................................................................................................................... 21 8.2. Stability calculation....................................................................................................................... 21 8.3. Overview of the different techniques............................................................................................ 22

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1.

1.1. Roll layout

A drawing showing the layout of each roll must be prepared to determine the number and size of each roll and to minimise wastage. Allowance needs to be made for the 20 cm seam overlap, anchoring surfaces and cuts.

1.2. Standard packaging of the rolls

In standard packaging, the rolls have the following dimensions:

Type NTP 1 / ES 1 NTP 2 / ES 2 NTP 3 / ES 3 NTP 4

Length 90 m 80 m 65 m 55 m

Width 5.10 m 5.10 m 5.10 m 5.10 m

Surface 459 m2 408 m2 331.5 m2 280.5 m2

The standard length of the steel mandrels is 5.47 metres, their inner diameter 15.5 cm, and their outer diameter 16.5 cm. A 20 cm strip, (located under the left side of the membrane in standard production) is covered with a kraft paper instead of terphane, in order to protect the seam edge. Most of the rolls are made of one single piece. However, due to manufacturing constraints some may have a transversal cut (no more than 20% for deliveries over 12 rolls). This is highlighted by a marker tape and the roll identification label.

1.3. Position of the Kraft paper

The standard position of the Kraft paper is on the left side when facing the strip while unrolling. For some applications (canals, etc) with seams that must be installed overlapping in the flow direction, it may be necessary for the Kraft paper to be positioned on the other side. This must be advised when ordering the membrane.

1. Materials

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1.4. Labelling of the rolls

The rolls are marked with the following labels: - Identification label, with the following information :

· Type of COLETANCHE · Length of the section(s) · Serial number

- ASQUAL label (for the certified membranes), - “Rouleau présentant une coupe – Roll in two pieces” label when

relevant.

1.5. Taking delivery of the rolls

A delivery note accompanies each delivery, with details of the roll dimensions and serial number. Check that this delivery note is in accordance with the numbers indicated on the rolls and the order. Carry out a visual inspection of the rolls, and carefully watch for possible damage (puncturing of the protection film). Sign the delivery note only after careful inspection of the delivery.

1.6. Unloading – temporary storage

Unloading costs are to be borne by the site. Unload the delivery lorries from the top, with a small beam equipped with slings or clamps to avoid damaging the membrane. Do not use forklifts, as they may damage the membrane. The hydraulic beam often used later during installation is also generally too bulky for unloading. Lay the rolls on the temporary storage area taking into account the future installation order on site (sorted by type of membrane dimensions, position of the Kraft paper, rolls in two pieces) to avoid unnecessary movement. Do not store the rolls directly on the ground (risk of puncture), but on specific supports, taking into account the distance between the bottom of the roll and that of the mandrel, which is about 35cm (two layers of concrete blocks, reinforced concrete beams, metal trestles, wooden beams).

1.7. Transfer of the rolls to the installation area

Transfer the rolls from the storage area and distribute them evenly along the site. The most convenient equipment is a boom truck, with an arm able to handle 2 tons at 3 metres distance. Store them on concrete or wooden blocks.

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1.8. Mandrels

A deposit is retained per mandrel, and is refunded when the mandrels are returned to the factory, provided they are in good condition, i.e.: - they should not be bent in the middle - the edges should not be flattened out - no welds or cuts around the three holes at the end of the mandrels (as these holes

are used to tension the membrane when rolling up during manufacture).

1.9. Production certificates

A certificate is sent with each delivery, which states that each roll complies with the requested specification. Individual certificates showing the test values of finished goods can be provided, if such a request is made when placing the order.

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2. Preparation of the subgrade

2.1. Surface aspect

The subgrade layer must be: - Free from sharp edges that might damage the membrane (sharp stones, etc), - Free from vegetation or organic content whose decomposition may lead to gas production and soil compressibility degradation. - Free from ruts where the membrane might get over tensed. Acceptable surface evenness tolerances: - On a large scale, up to 5cm under a 3 metres straight edge, - No defects on a scale of a few centimetres. Prepare the subgrade carefully, with levelling and mechanical compaction, and often a hand clearing of the surface with a rake. Fill in defects either with sand on the horizontal parts, or with lean mortar on the slopes. However, it may be necessary to lay a protection geotextile between the subgrade and the geomembrane, with a mass per unit area between 300 and 700gm/m2, depending on the grading and the angularity of the embedded stones inside the subgrade, or to use a higher grade COLETANCHE.

2.2. Slopes

The COLETANCHE membrane can be laid without any problem on slopes up to a ratio of 3 horizontal to 2 vertical. Small areas with a steeper slope can however be covered with COLETANCHE, provided it is fully bonded by torching to the concrete support, or evenly spaced metal fixings or intermediate anchoring are used.

2.3. Transition area at foot of a slope

The transition between the slope and the bottom of the structure must be as smooth as possible, with a rounded shape with a minimum radius of 20cm. The bottom of the reservoir or ponded area must also have a 3 to 4 % gradient, in order to correctly drain the site, and in case the reservoir or ponded area needs to be drained in the future.

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2.4. Bearing capacity

The purpose of the membrane is to guarantee the waterproofing of the structure. It does not increase the structural capacity. The subgrade needs to have a good bearing capacity: - CBR above 10 - Stiffness modulus above 50MPa

2.5. Hand over procedure

Carry out a visual inspection of the subgrade together with the Client and the company in charge of the construction of that layer, before starting the waterproofing operations. Investigate all possible problems (quality of the subgrade, damage to concrete,etc) on the support layer acceptance form. Do not hesitate to refuse a subgrade if its quality is not as good as requested.

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3. Installation

3.1. Typical crew

A typical laying crew includes: - a foreman - three operatives for membrane handling and temporary anchoring - an excavator driver

If the unrolling beam is not equipped with a hydraulic motor, at least two additional workers must be provided to pull the strips. If the support layer quality is bad, (sharp stones or ruts), and requires correction just before laying the membrane, additional workers with rakes should be included.

3.2. Heavy equipment

Rolls are handled with a 20 to 25 tons hydraulic excavator, if possible tracked. There are two kinds of handling beams:

- Hydraulic beams, connected to the hydraulic pipe of the bucket - Manual beams, more or less sophisticated, which require pulling on the

membrane, with a risk of running out of control. The beams must in that case be equipped with a braking system.

It may also be necessary to provide a winch on the opposite side of the site when long lengths are installed (friction effect between the membrane and the ground).

3.3. Personal protection equipment

General construction safety regulations apply to membrane installation projects. PPE will therefore include in particular: - Safety shoes or boots - Safety helmets for staff moving within the roll handling area - Safety jackets - Handling gloves - Heat resistant gloves - Safety harness and anchoring system

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3.4. Small equipment

The small equipment consists of: - Blacksmith clamps with welded plates at the end, to maximise the surface contact

with the membrane - Cutters with hooked blades. Flat blades are not suitable for cutting COLETANCHE

due to its internal geotextile - Pruning knives - Surveyor’s staff - Builders line - Measuring tape - Aerosol paint - Rope ladders

3.5. Weather conditions

Do not lay the membrane: - If the wind speed is above 40 km/h - When the air temperature is above 30°C, as the shoes of the workers will leave

prints on the surface - When the air temperature is below 5°C for COLETANCHE NTP, and -25°C for

COLETANCHE ES, as the membrane becomes too stiff.

3.6. Laying technique and procedures

Laying COLETANCHE is in most cases carried out with the terphane (bright plastic film) down. Remove the polyethylene interleaving separating film. Laying starts from the highest slope, according to the lay out scheme previously established. Hold the membrane either with blacksmith clamps, or through notches at the end of the strips.

3.7. Overlap width

Mark the position of the membrane with builder’s line or painted marks, to define a minimum 20cm overlap.

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3.8. Transverse joints

Lay the strips in such a way to avoid: - Transverse seams on slopes except in exceptional cases - Quadruple overlaps due to misaligned roll ends. Triple overlaps will be covered

with an additional membrane to protect the installation and will be carefully monitored in any case.

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4. Anchoring – ballasting

4.1. Effects of wind

Temporary ballasting of the strips must be carried out with particular care as soon as they are laid and also at the end of each day if all welds are not completed.

4.2. Temporary ballasting

Ballast the membrane with 10 to 20kg sand bags, concrete blocks, filled tyres or non sharp materials, evenly distributed on the membrane surface, and especially adjacent to the laps to reduce the effect of wind during construction phase.

Hang the bags on the slope with a rope attached on the crest.

4.3. Final ballasting

The proper execution of this task is essential to the behaviour of the membrane and to prevent creases along the slope.

4.3.1. Trench anchoring (most frequent case)

Bury a section of membrane in a trench dug either by hand or with an excavator or grader, depending on the access to the crest. It should be prepared whenever possible before laying the membrane, to avoid unnecessary and potentially damaging movements of the membrane.

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4.3.2. Anchoring through flat ballasting

Hold the geomembrane in place with ballasting materials, avoiding erosion effects.

Estimate of the required ballast:

Length of the

slope Little or

moderate wind

Strong winds

0 to 3 m 0.04 0.06

3 to 5 m 0.09 0.16

5 to 15 m 0.16 0.35

More than 15 m 0.25 0.36

Ballast in m2 / m, for a 2 ton per cubic metre material (around 20 kN / m3) Anchoring must be carried out with metal pins, driven into the ground, which will remain in place after the final anchoring. Backfill the anchoring trench to avoid water accumulation, which might destabilise the ground if the weather is wet. Wait until the structure is put into operation if the support layer is likely to settle, so that the membrane reaches its final position with minimal internal tensions.

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5. Laps

5.1. Typical manual welding crew

A typical manual welding crew includes : - A welder - A helper for rolling - Possibly an additional worker if the preparation of the seam requires it (dirty membranes exposed to mud or wind, etc.) The welder leads the whole operation, setting the pace and directing the helper, as weather conditions and the condition of the bitumen may require. For safety reasons, even if only a few strips are involved, a welder must never operate alone on a site.

5.2. Equipment for manual welding

The equipment required for manual welding includes : - Propane gas torch with a flat burner with 4 holes, with a lance and a trigger handle

with adjustable flow - 13 or 30 kg propane gas bottles, with a hand truck and adjustable pressure valve

between 0 and 3 bars - Flexible gas feed pipe, long enough to allow welding of a whole strip without

having to move the bottle - Heatproof gloves in accordance with regulations - Small trowel - Fire extinguisher with powder or carbon dioxyde For rolling the seams, the following equipment must be supplied: - A 10 to 15 kg metal roller, 20 cm wide to be used on flat surfaces - A 5kg roller for the slopes and details - A bowl of wet rags, possibly mounted on a shaft (mop) for details - A bucket of water - A scraper to remove bitumen runoff that may accumulate on the rollers

5.3. Weather conditions

When welding, the air temperature must be between + 5°C and + 30°C Do not weld in presence of water as it vaporises on contact with hot bitumen and creates bubbles that will remain within the seam. Only a slight dampness is allowed.

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5.4. Technical details

Carefully brush the seam area to remove loose sand. Remove the Kraft paper at the last moment. Clean mud traces with a sponge. Remove any sharp stones that may still lie under the membrane, as their presence would hinder the proper rolling of the seam. Carefully burn in advance the terphane film where present, after turning the membrane upside down.

Weld first of all a 50cm long area, which joins together the two strips, and roll it carefully. Move with a continuous steady pace, and, with one hand, or possibly with a hook, lift the upper membrane about 10cm, and insert the torch between the two strips, while keeping the flame aligned with the edge in order to heat the 20cm width in one single run. Carry out the rolling 1.50 or 2.00 metres behind the burner, i.e. about 1.00 metre behind the flame. Always weld upwards on slopes. Roll vigorously, to get a good contact between the two sides. Do not step on a hot seam, as footprints will remain on the soft bitumen. A bitumen edge must ooze when rolling, to a width up to 3cm. Do not apply the roller on this bitumen edge; otherwise it gets contaminated, and then sticks to the upper surface of the membrane. Adjust the forward speed and the torch power to control the amount of heat applied to the seam. Check visually the seam once it has cooled down. Proceed to the finishing works, through reheating the edge and shaping it as a fillet, possibly with a small trowel.

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5.5. Protection of geotextile against flame damage

Sometimes a geotextile is applied as a protective layer under the geomembrane. If it is made of polypropylene, it may be damaged when welding by the heat of the flame and melted bitumen run off. The damaged surfaces are generally very small, but nevertheless it may be advisable to lay a thermal protection between the geotextile and the geomembrane. A 100 to 300 gm/m2 glass fleece in 35 to 100 wide strips offers a good protection.

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6. Construction details

6.1. Connection to structure

Such connections must be dealt with during the design phase, through recommending the use of rounded angles and fillets. Backfill compaction around those specific details must be carefully carried out with correct equipment in order to minimise differential settlement. Good construction procedures, as detailed below, may reduce the consequence of possible settlement. In the case of connection to a concrete structure: First check that the concrete is dry, after at least 28 days drying, and that it is free, possibly through brushing down, of its skin layer. Apply a cold primer, to a quantity of 300 gm/m2 of residual binder (type Vernis ANTAC GC), and wait until the solvents evaporate. Classical bituminous emulsions are prohibited. Then weld in a classical way through heating both the membrane and the concrete surface, and roll with a small roller, mop or a bowl of wet rags. To increase the connection durability, a plate made of stainless steel, aluminium or plastic can be applied, through bolting or tacking into the concrete. This fixation may then be protected either by an additional COLETANCHE strip, or through a Bitumseal bituminous binder cover.

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6.2. Connection to water inlets and outlets

The same precautions must be taken when connecting the geomembrane to inlet or outlet pipes. Cast a small concrete block around the head of the pipe, so as to connect the main layer of the membrane, and then coat the pipe with an additional membrane. Waterproofing around the pipe is ensured either through a polyurethane seal inserted inside the concrete block when casting it, or through connecting the cover around the pipe through welding or with Bitumseal depending on the pipe’s resistance to flame. This connection may then be reinforced using a clamp collar.

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7. control

7.1. Total control – statistical control

Depending on the requirements of the contract and/or the commitments made within the C.Q.A. plan, two different types of controls can be carried out on the seams: - A 100% control, which requires many staff and equipment - A statistical control carried out on a defined percentage of the seam length, with extra testing at sensitive points. The test frequency increases if flaws are detected. In all cases, it is strongly advised to carry out a total control of the first welds executed by each of the welders on a new site, whether a trial section is required or not.

7.2. Visual assessment

The first control method is carried out by the welder himself: Check visually the width and quality of the seam Check the presence of the bitumen edge Try to insert a small trowel or a flat spike between the two strips Carry out the finishing works

7.3. Compressed air pressure testing

A compressed air head along the seam shows weld discontinuity similarly to the insertion of a trowel or a spike, by loosening of the upper membrane.

7.4. Vacuum bell testing

The vacuum bell checks the watertightness of a seam but does not give any information as to its mechanical behaviour. This method is recommended for a statistical testing, and mostly for critical details (triple seams). Wet the edge of the seam with a soap solution. Apply through a vacuum pump, a 200 to 400 mbar depression inside a plexiglas bell for 15 to 20 seconds.

Any leakage is revealed by air bubbles.

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7.5. Echograph testing

In Echograph testing ultrasonic pulses are emitted on the surface of the overlap. If there is a discontinuity of the weld (air bubble, dirt), an intermediate echo is detected, which appears on the echograph screen, and a sound signal draws the operator’s attention.

The most commonly used equipment is based upon a portable echograph, such as PANAMETRICS EPOCH types. Scan the surface with a transducer to identify weakness areas. Keep the surface wet, either by water on flat surfaces, or with wallpaper paste on slopes. Indicate the flawed areas with paint for further treatment. French road administration regulations have the following requirements : - 15 cm weld for oxidised bitumen membranes (type COLETANCHE NTP) - 12 cm weld for elastomeric bitumen membranes (type COLETANCHE ES) Check that a minimum 13 cm width can be guaranteed in every point if those specifications do not apply to the particular job.

7.6. Automatic continuous testing

Based upon the same ultrasonic testing principle, the CAC process provides an automated continuous control. A wheel with 24 transducers scans in one path the whole width of the lap, and sends to a computer the position of the flaws and their severity, based on levels defined by the user. Paper printouts show the location on site, but also guarantee a full traceability within the C.Q.A. This equipment is self powered and an additional winch can be used to pull it on slopes.

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7.7. Destructive testing

Final testing method: samples of laps are removed on which longitudinal tensile strength tests are carried out. (e.g. according to French standard NF P 84 502-1). The French Committee on Geosynthetics defined the following acceptance criteria for weld resistance, in kN:

Membrane thickness (mm) 3.5 4.0 4.8 5.6

Bituminous binder (kN/m) 7.0 9.0 10.0 12.5

Elastomeric binder (kN/m) 13.0 15.0 16.0 18.0 7.8. Repairs of bad quality welds and creases

Non conforming laps, serious creases and more generally all damage must be repaired, with an additional layer of membrane. The patch dimensions must be at least 20cm larger on each side than the defect area. Preparation - the patch is prepared with rounded edges. Weld the membrane on its whole surface, after carefully burning the terphane. An additional test using the previous methods can then be carried out again. On existing projects where the membrane was already covered either by a protective layer, or by waste materials or mud, repairs to the membrane can be carried out in the same way, after carefully cleaning the membrane with high pressure water (50 to 120 bars). A new membrane can easily be connected to an older one.

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8. Protection

8.1. Specific precautions

Installing a protective layer upon COLETANCHE does not create any problems, provided the following points are carefully followed: Adapt the protective layer to the structure and its future use (risk of erosion, settlements, puncture by the protective layer). Check the stability of the protective layer on the geomembrane (risk of sliding of the protective layer, risk of tension inside the membrane under the weight of the protective layer). Install the protective layer with adequate equipment : · If the bearing capacity of the sub-base allows it, traffic, even heavy (finishers,

supply trucks), can be temporarily allowed, provided no tension is generated inside the membrane (flewing)

· Nevertheless, in most cases, it is best to lay the protective layer with an excavator from outside the structure (from the crest), or to place it with a small loader or bulldozer, moving on the layer already laid.

8.2. Stability calculation

Friction angles between different protective materials and COLETANCHE are given in the next table:

Material Side Friction angle

Gravel 0/31.5 mm Smooth 33 to 37 °

Sand 0/5 mm Smooth 25 to 28 °

Non woven polyester geotextile Smooth 21 to 23 °

Gravel 0/31.5 mm Sanded 38 to 44 °

Sandy humus Sanded 36 to 42 °

Clay humus Sanded 39 to 42 °

Non woven polyester geotextile Sanded 32 to 38 °

Geogrid (type ENKAMAT) Sanded 27 to 36 °

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Drainage grid (type ENKADRAIN) Sanded 36 to 44 °

In situ cast concrete after 15 min. Sanded 36 to 43 °

In situ cast concrete after 8 days Sanded > 45 °

8.3. Overview of the different techniques

8.3.1. Hot mix asphalt or macadam

Bituminous geomembranes show a major difference compared to other synthetic membranes, which is its compatibility with hot mix asphalt or macadam. With a thickness of 5 to 8cm, a maximum grading of 10mm, and a rich mix-design (bitumen content increased by 0.5 to 1.0% compared to standard recipes), hot mix asphalt can be laid directly upon the membrane, without laying an intermediate geotextile. When laying hot mix asphalt, temporary creasing may appear, but this does not have any consequence on the membrane behaviour. Cold asphalt mixes may also be used as a protective layer. If the grading is above 14mm, it may be necessary to lay an intermediate 250gm/m2 polypropylene geotextile to avoid puncturing the thinner COLETANCHE membranes (NTP / ES 1 et 2).

8.3.2. Concrete - cobblestones

A protective layer, either rigid (in-situ cast concrete slabs) or supple (cobblestones), can be laid on the COLETANCHE membrane. A 250 to 500 gm/m2 polypropylene geotextile is generally laid in between them. Cobblestones can be contained either by a foot abutment, or anchored with stainless steel cables from the crest. 8.3.3. Gravel - ballast

As for cold mix asphalt, laying a geotextile between the COLETANCHE and the protective layer made of gravel or ballast depends upon the aggressiveness of the material (grading, angularity), and mostly upon the type of COLETANCHE used. Gravel and ballast are laid with a minimal thickness of 20cm. If those materials are laid by pushing forward with a loader or a small bulldozer, then friction may generate a slight elongation of the membrane. To avoid creases that may then collapse, it is advised to leave one end of the membrane free, and weld it only at the end of the work phase.

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8.3.4. Rocks - gabions

The bearing capacity of the sub-base is a key factor when laying rocks or gabions to prevent the membrane from tearing under the weight of the protection. A thick geotextile (800 to 1,000gm/m2) is often advised between the membrane and the protective layer.

8.3.5. Top soil – grassing – planting

Top-soil covered with grass or planting is another solution to protect COLETANCHE. If the slopes are too steep for the internal friction angle of the top-soil, it can be maintained through the use of honeycomb mesh. Grass, reeds or small tree roots do not punch the geomembrane. For larger trees, species with flat roots are to be chosen.