Firestone EPDM Installation Specification

PART 1. GENERAL

1.1 SCOPE OF WORK

A. The work covered by this specification consists of providing and installing a reinforced or non-reinforced as specified by the Project Engineer vulcanized rubber sheet made from ethylene propylene diene terpolymer (EPDM) for use as a geomembrane.

1.2 REFERENCES

A. American Society for Testing and Materials

D413 Test Method for Rubber Property - Adhesion to Flexible Substrate
D471 Test Method for Rubber Property - Effect of Liquids
D618 Practice for Conditioning Plastics and Electrical Insulating Materials for Testing
D638 Test Method for Tensile Properties of Plastics
D751 Test Methods for Coated Fabrics
D792 Specific Gravity (Relative Density) and Density of Plastics by Displacement
D1004 Test Method for Initial Tear Resistance of Plastic Film and Sheeting
D1149 Test Method for Rubber Deterioration - Surface Ozone Cracking in a Chamber
D1204 Test Method for Linear Dimensional Changes of Non-rigid Thermoplastic Sheeting or Film at Elevated Temperature
D1505 Test Method for Density of Plastics by the Density-Gradient Technique
D2137 Test Method for Rubber Property-Brittleness Point of Flexible Polymers and Coated Fabrics
D4437 Standard Practice for Determining the Integrity of Field Seams Used in Joining Flexible Polymeric Sheet Geomembranes
D4439 Standard Terminology for Geosynthetics
D4545 Standard Practice for Determining the Integrity of Factory Seams Using in Joining Manufactured Flexible Sheet Geomembranes
D4833 Test Method for Index Puncture Resistance of Geotextiles, Geomembranes, and Related Products
D5199 Test Method for Measuring Nominal Thickness of Geotextiles and Geomembranes
D5261 Test Method for Measuring Mass per Unit Area of Geotextile
D5321 Standard Test Method for Determining the Coefficient of Soil and Geosynthetic or Geosynthetic Friction by the Direct Shear Method
D5514 Test Method for Large Scale Hydrostatic Puncture Testing of Geosynthetics
D5617 Test Method for Multi-Axial Tension Test for Geosynthetics
D5721 Standard Practice for Air-Oven Aging of Polyolefin Geomembranes
D5884 Test Method for Determining Tearing Strength of Internally Reinforced Geomembranes
E96 Test Methods for Water Vapor Transmission of Materials
G53 Practice for Operating Light-and Water-Exposure Apparatus (Fluorescent UV-Condensation Type) for Exposure of Nonmetallic Materials

B. National Sanitation Foundation:

NSF 54 Flexible Membrane Liners (FML).

1.3 SUBMITTALS

A. Sheet Layout and Detail Drawings: Submit PondGard panel layout, anchor trench and penetration detail drawings a minimum of 30 days prior to delivery of PondGard to a jobsite.

B. Record "As-Built" Drawings: Provide final record "As-Built" Drawings of PondGard installation showing panel/sheet numbers, seam numbers, and location of patches, destructive seams samples, and any penetrations.

C. Instructions:

1. Submit manufacturer's installation manual, showing seaming techniques, and suggested installation procedures.

2. Submit certification from the CQA Inspector and Installer of the acceptability of the surface on which the PondGard is to be placed immediately before the PondGard placement.

3. Submit one sample 12" x 12" with one factory seam.

1.4 QUALITY ASSURANCE

A. Installer is responsible for field handling, deploying, seaming, anchoring, and field quality control testing of PondGard and shall have installed similar geomembrane material. At least one person shall have experience seaming the PondGard material using the thickness and seaming method as specified in this project.

B. CQA Inspector shall be hired by the Installer, with the approval of the Owner and Project Engineer, as a third party quality assurance person or corporation, that is independent from the manufacturer and Installer. CQA Inspector shall be responsible for monitoring and documenting activities related to the quality assurance of the PondGard from manufacturing through installation. Inspector shall have provided quality assurance inspection during installation of similar geomembranes.

C. Independent laboratory shall be hired by the Installer with the approval of the Owner and Engineer, as a third party quality assurance laboratory, independent from the manufacturer, fabricator, and the Installer. Independent laboratory shall be responsible for laboratory quality assurance PondGard testing. Independent laboratory shall have provided quality control or quality assurance testing of similar geomembranes.

D. Equipment used in the performance of installation and seaming shall be in accordance with the PondGard manufacturer's recommendations and shall be maintained in satisfactory working condition.

1.5 DELIVERY, STORAGE AND HANDLING

A. Protect PondGard from punctures, abrasions, excessively hot or cold temperatures and other damaging conditions.

B. Deliver materials to the job site in their original containers as labeled by the manufacturer. Follow manufacturer's directions for protection of materials before and during installation. Do not use damaged materials. Remove damaged PondGard from the Project site at no additional cost to the Owner.

C. The Installer shall visit the site to check whether the excavation work has been performed correctly performed.

D. In no event shall the PondGard be placed over rocks or other materials, which are capable of puncturing or stressing the PondGard. The ground surface shall be free of all damaging debris and sharp objects before placement of the PondGard. PondGard shall be deployed and field-seamed only when PondGard is dry, free of dust, dirt and foreign material.

PART 2 PRODUCTS

2.1 MATERIALS

A. Raw materials used in manufacturing PondGard shall be made of virgin and uncontaminated ingredients. Roll goods are to be manufactured from EPDM polymers and other compounding ingredients. Roll goods material shall be capable of bonding to EPDM for making a watertight system. Regrind, reworked, or trim materials shall be from the same manufacturer and exactly the same formulation as the PondGard roll goods produced. Materials with previous service life that are recycled shall not be allowed.

B. EPDM materials are defined as a manufactured seamless PondGard unit with a width equal to or greater than 5 feet. Materials shall be reinforced EPDM or non-reinforced PondGard as specified by the Project Engineer and uniform in color, thickness and surface texture. PondGard shall be resistant to fungal or bacterial attack and free of cuts, abrasions, holes, blisters, contaminants and other imperfections.

C. EPDM roll goods and factory seams shall conform to the minimum physical requirements listed in Table 1. Test values shown in Table 1, except when specified as nominal are the typical minimum values.

D. Raw materials shall be tested in accordance with the approved PondGard manufacturer's quality control procedures at plant of manufacture. Materials that fail to meet the PondGard manufacturer's specified physical properties shall not be accepted for manufacturing the roll goods.

E. PondGard roll goods shall be randomly sampled and tested in accordance with the manufacturer's approved quality control procedures. Materials not meeting the minimum requirements specified in Table 1 shall be rejected.

F. Roll goods or fabricated panels shall be visually inspected for defects and impurities. Thickness measurements shall be made at the center of each edge of the beginning and end of each roll or panel in accordance with the method specified in Table 1. All rolls or panels having a thickness less than 90% the test value specified in Table 1 will be rejected.

TECHNICAL SPECIFICATIONS TABLE 1
EPDM PONDGARD
Reinforced EPDM PondGard EPDM
Property Test Method Test Value Test Method Test Value

Thickness - nominal ATM D-5199 45 mil (1.15 mm) ASTM D-5199 45 mil (1.15 mm)
Specific Gravity - nominal ASTM D-792 1.10 ASTM D-5199 1.10
Unit Weight -nominal ASTM D-5261 0.28 lb./ft.2 (1.4 kg/m 2) ASTM D-5261 0.28 lb./ft.2(1.4kg/m 2)
Tensile Properties: (1)
Break Strength (min.) ASTM D-751 190 lb. (850 N) ASTM D-882 55.0 lb./in. (250N)
Break Elongation (min.) ASTM D-882 600 %
Tear Resistance (min.) ASTM D-5884 130 lb. (580 N) ASTM D-1004 9 lb. (40 N)
Puncture Resistance (min.) ASTM D-4833 60 lb. (270 N) ASTM D-4833 35 lb. (160 N)
Oven Aging
100ºC for 170 hours ASTM D-573
% Retained Tensile Break Strength ASTM D-792 90 % ASTM D-882 90%
% Retained Tensile Break Elongation ASTM D-882 75%
Resistance to Ozone - 7 days ASTM D-1149 No cracks ASTM D-1149 No cracks
100 pphm @ 100ºF (37.8ºC) with 50% extension
Brittleness Temperature ºF (ºC) ASTM D-2137 -49(-45) ASTM D-2137 -49(-45)
Water Resistance - change in weight ASTM D-471 8% ASTM D-471 8%
after immersion 7 days @ 150ºF (65.6ºC)
Water Vapor Permeability ASTM D-96 2.0 perm-mils ASTM D-96 2.0 perm-mils
Dimensional Stability ASTM D-1204 1% ASTM D-1204 1%
Specialty Testing FBP - 1094
Independent laboratory testing used to determine toxicity of EPDM membrane Passes test Using Shubunkin goldfish
(1) Machine direction (MD) and cross machine direction (XMD) average values are based on five test specimens in each direction.
These products are special order items requiring a minimum of two-week lead-time for production.
Seaming Minimum Values (after 24 hour cure time)
Shear ASTM D413 / lb./in. 35
D4437 NSF modified at 200% strain
20 i.p.m. strain rate

Peel ASTM D413 / lb./in. 14*
D4437 NSF modified
20 i.p.m. strain rate
* Cohesive bond mode / FTB tape

2.1 WARRANTY

A written 10-year membrane warranty shall be obtained from the Manufacturer (for material). Upon notice of completion from the Installer, Firestone Building Products shall issue their limited material warranty.

PART 3 EXECUTION

3.1 SUBGRADE PREPARATION

A. Surface Preparation: Perform in accordance with project specifications. Loose rock larger than ½ inch in diameter and other debris that could damage the PondGard shall be removed from the surfaces to be covered with PondGard. Construction equipment track deformations shall not be greater than 1 inch in depth. CQA inspector shall observe subgrade surface daily and Installer shall evaluate the surface conditions. Damage to the subgrade by the Installer shall be repaired at no additional cost to the Owner. Immediately before PondGard placement, CQA inspector and Installer shall certify in writing to the Owner that the surface the PondGard is to be placed on is acceptable.

B. Anchor Trenches: Only the amount of trench required for the PondGard to be anchored in one day shall be excavated. Trench corners shall be slightly rounded to avoid sharp bends in the PondGard. Loose soil, rocks larger than ½ inch in diameter, and other debris that could damage the PondGard shall be removed from downslope edge of trench. Select fill shall be utilized as backfill material in anchor trenches in accordance with the specifications for backfill.

3.2 PONDGARD PANEL PLACEMENT

A. PondGard shall be placed with minimum handling and in accordance with the Firestone's recommendations. Procedures and equipment used shall not damage the PondGard. PondGard damaged during installation shall be removed or repaired at the CQA Inspectors discretion and as specified in the Section 3.5 at no additional cost to the Owner. Only those panels that can be anchored and seamed together the same day shall be deployed. Adequate ballast shall be placed on the PondGard to prevent uplift by wind without damaging the PondGard. The method used to unroll panels shall not stress or damage the PondGard as determined by the CQA Inspector. Seams shall be oriented parallel to the line of MAXIMUM slope.

B. Wrinkles: The method used to place PondGard panels shall minimize wrinkles. Provide sufficient slack in the deployed PondGard to prevent tensile stresses in the PondGard or its seams during the installation and after PondGard is covered.

C. Thickness Measurement: A minimum of five thickness readings shall be taken along the edge across each panel width and at least two thickness measurements shall be taken along each panel length in accordance with ASTM D 5199. Panels whose thickness falls below the specified minimum value shall be rejected and replaced.

3.3 FIELD SEAMING

All field seaming shall be in accordance with Firestone approved methods. All materials and accessories must be Firestone approved.

A. Trial Seams: Trial seams shall be made on test strips of excess PondGard EPDM under field conditions to verify that seaming conditions and materials are adequate. Trial seams shall be made each day before production seaming, whenever there is a change in seaming personnel and at least once every four hours. One sample shall be obtained from each trial seam. Sample shall be at least 24 inches in length and 12 inches in width with the seam centered lengthwise. Six random specimens, one inch in width shall be cut from the sample. Three seam specimens shall be tested for shear strength and three for peel adhesion using an approved field tensiometer. Jaw separation speed shall be 20 in/min. To be acceptable two out of three replicate test specimens shall meet specified seam strength requirements as shown in Table 1 after 24 hours cure time. If the field tests fail to meet these requirements, the entire operation shall be repeated. If the additional test seam fails the seaming crew and materials shall not be accepted or used for seaming until the deficiencies are corrected and two consecutive successful test seams are fabricated.

B. Field Seams - General Requirements: Panels shall be overlapped a minimum of 4 inches. Seaming shall extend to the outside edge of panels to be placed in anchor trenches. Seaming shall not be conducted in the presence of moisture, dust, dirt, standing water or soft subgrade as determined by the CQA Inspector. Wet surfaces shall be thoroughly dried and soft subgrade compacted and approved by Project Engineer and CQA Inspector before seaming. Seam area shall be cleaned of dust, dirt, and other foreign material prior to and during seaming.

3.4 FIELD SAMPLING AND TESTING

A. Non-Destructive Field Seam Testing: Field seams shall be non-destructively tested over their full length in accordance with ASTM D 4437 to ensure seam continuity. Seam testing shall be performed as the seaming work progresses, not at the completion of field seaming. Seams that fail shall be documented and repaired in accordance with the manufacturers approved quality control manual.

B. Destructive Field Seam Testing: Destructive seam test sample shall be taken at intervals as required and agreed upon by all parties and at locations specified by the CQA Inspector. Samples shall be a minimum of 12 inches in width by 36 inches in length with the seam centered lengthwise. Each sample shall be cut into three equal pieces with one piece retained by the Installer, one piece given to the Independent QC Laboratory, and the remaining piece given to the Owner for quality assurance testing and permanent record. Each sample shall be numbered and cross referenced to a field log which identifies: panel number, seam number, date and time cut, ambient temperature, and the name of the seamer. A minimum of four 1-inch width replicate specimens shall be cut from the Installer's sample. A minimum of 2 specimens shall be tested for shear strength and 2 for peel adhesion using an approved field tensiometer. Jaw separation speed shall be 20 inches per minute. To be acceptable, replicate test specimens shall meet the specified seam strength requirements as shown in Table 1. If the field-test pass, 5 specimens shall be tested at the Independent Laboratory for shear strength and 5 for peel adhesion in accordance with ASTM D 413 and D 4437/NSF Modified. To be acceptable, 4 out of 5 replicate test specimens shall meet specified seam strength requirements. If field or laboratory test fail, the seam shall be repaired in accordance with the Section 3.5. Certified test results on field seams shall be submitted to and approved by the CQA Inspector prior to acceptance of the seam.

3.5 REPAIRS

A. Destructive Seam Test Repairs: Defective seam areas shall be cap striped with a strip or strips of new material and seamed. After cap stripping, the entire cap stripped seam shall be non-destructively tested. Certified test results on repaired seams shall be submitted and approved before covering of the seamed areas.

B. Repair Patches: Tears, holes, blisters, and areas with undispersed raw materials or foreign material contamination shall be repaired with patches. Patches shall have rounded corners, be made of Firestone EPDM and extend a minimum of 6 inches beyond the edge of defects. Repairs shall be non-destructively tested.

3.6 PENTRATIONS

PondGard penetration details shall be as shown on the Drawings and as recommended by the PondGard manufacturer. Factory fabricated boots shall be used wherever possible. All field-fabricated flashings shall be made of Firestone QuickSeam FormFlash. Field seams shall be non-destructively tested in accordance with the manufacturer's approved methods. Seams that fail non-destructive testing shall be repaired and non-destructively tested before acceptance.

3.7 COVER SOILS

PondGard shall be covered with the required geosynthetic or soil cover material within 7 days of acceptance. Folding over of PondGard wrinkles is allowed before or during placement of cover soil, as stress cracking is not an EPDM performance issue.

END OF SECTION

The data in this document is for informational purposes only, it subject to periodic revision and does not constitute a warranty or guarantee. Firestone Building Products assumes no responsibility for the use of this information. Application of this information for any project is to be at the recommendation of the project engineer. Contact Firestone Building Products for the most current information or additional EPDM product selection criteria.