Installation QAQC Manual

Sinotech
GEOSYNTHETICS
Geomembrane
Installation Quality Assurance Manual
www.sinotechgeo.com
Introduction
INSTALLATION QUALITY ASSURANCE MANUAL
Installation
Manufacturing and
delivery
Sinotech Environmental Technologies Limited

Installation Quality Assurance
Policies and Procedures
This manual contains proprietary information belonging to Sinotech Environmental Technologies Limited. Any information
contained herein is not to be discussed with others outside the involved organizations, except with the express prior written consent
of Sinotechs management.
This manual replaces in its entirety and supersedes all earlier versions issued by Sinotech Environmental Technologies Limited. We
suggest you maintain contact with your Sinotech representative to confirm the validity of this version at future dates.
Appendix
Standard specification
for HDPE lining material
Welder start-up and

basic operation
Pre-start site inspection
Detail drawings
Details of welding
systems
Sinotech Environmental Technologies Limited reserves the right to change, modify, or discontinue the use of the policies and
procedures described herein without notice or prior consent except as contractually obligated to do otherwise.
SINOTECH GEOMEMBRANE INSTALLATION QUALITY ASSURANCE MANUAL
INTRODUCTION
Introduction
Sinotech
GEOSYNTHETICS
1.1 Terms of Reference

Manufacturing and
delivery
1.1.1 Purpose
This manual addresses the quality assurance and quality control of the installation of flexible membrane liners and other
geosynthetic products used by Sinotech Environmental Technologies Limited in hazardous waste disposal landfills, surface
impoundments, or other installations as specified by the owner and/or engineer. The manual therefore delineates the quality
procedures and standards for production and installation.
1.1.2 Quality Assurance and Quality Control
In the context of this manual, quality assurance and quality control are defined as follows:
Quality Control - Those actions which provide a means to measure and regulate the characteristics of an item or service to
contractual and regulatory requirements.
Installation
Quality Assurance - A planned and systematic pattern of all means and actions designed to provide adequate confidence that
items or services meet contractual and regulatory requirements and will perform satisfactorily in service.
In the context of liner production and installation:
1.1.3 Lining Materials

The materials comprising the lining system include geosynthetics: geomembranes, bentonite blankets, geotextiles, and
geonets manufactured from synthetic polymers.
The quality assurance of a geosynthetic liner system is addressed herein in its entirety, including all stages from manufacturing
to installation. The quality assurance of soils is only discussed relative to their interaction with geosynthetics.
This manual does not address design guidelines, installation specifications, or selection of geomembranes and other
geosynthetic materials (which includes compatibility between geosynthetic and contained materials).
1.1.5 Units
In this manual, all properties and dimensions are expressed in SI units with equivalent English units in parenthesis. It should
be noted that the conversion is typically only accurate within ten percent. In cases of conflict or clarification, the SI units shall
be deemed to govern.
Appendix
1.1.6 References
This manual includes references to test procedures of the American Society for Testing and Materials (ASTM). Recognizing
the changing nature of the above standard and the geosynthetic industry at large, this manual is subject to periodic revisions.
This manual does not address the quality assurance of soils, except in cases where soil placement may have an influence on
the geosynthetic materials.
Welder start-up and

basic operation
1.1.4 Scope of Quality Assurance and Quality Control

The scope of this manual includes the quality assurance applicable to manufacturing, shipping, handling, and installation of all
geosynthetics. In particular, full time quality assurance of the installation of geomembranes and the installations of other
geosynthetic essentials.
The geomembranes are utilized either alone or in conjunction with low permeability soils and/or bentonite blankets as
composite liners. Geomembranes are the key components of the lining system, and therefore, none of the geomembrane
requirements contained herein should be compromised in any way. Geotextiles, geonets, and granular soils are utilized in
combination for leachate collection systems.
Detail drawings
For purpose of this document, the term geomembrane is applied to flexible membrane liners. More specifically
geomembrane refers to polyethylene geomembranes, with either smooth surface or textured surface or increased friction.
These geomembranes include high density polyethylene (HDPE) membranes which are made from resins with a specific
gravity greater than 0.934 and linear low density polyethylene (LLDPE) membranes which are made from resins with a specific
gravity between 0.89 and 0.91 prior to the addition of carbon black and additives.
Details of welding
systems
Quality assurance refers to means and actions employed by Sinotech to assure conformity of the lining systems and
production with the Quality Assurance Plan, drawing, and specifications.
1.2 Parties (refer to the flow chart on the next page)

1.2.1 Designer
The Designer is responsible for the design, drawing, plans, and specifications of the lining system.
1.2.2 Earthwork Contractor
The Earthwork Contractor is responsible for the preparation of the supporting soil on which the lining systems is to be installed,
and may also be the party responsible for placing earth and granular materials (if any) over the installed lining system.
Manufacturing and
delivery
Introduction
INTRODUCTION
1.2.3 Resin Supplier

The Resin Supplier produces and delivers the resin to the manufacturer.
1.2.4 Geomembrane Manufacturer (Sinotech)
The Geomembrane Manufacturer is responsible for the production of geomembrane rolls from resin.
Installation
1.2.5 Installer
The Installer is responsible for field handling, placing, seaming, field testing, temporary loading (against wind), and other
aspects of the geosynthetic installation.
Details of welding
systems
1.2.6 Transporter
The Transporter transports the rolls of geomembrane between the Geomembrane Manufacturer and the site.
1.2.7 Soils Quality Assurance Consultant
The Soils Quality Assurance Consultant is normally a party, independent from the Owner, Geomembrane Manufacturer, and
Installer that is responsible for observing, testing and documenting activities related to the quality assurance of the earthwork
at site. He is also responsible for issuing a certification report.
1.2.9 Owner
The Owner owns, and/or is responsible for the lined facility. In this manual the term Owner shall apply equally to Operator:
i.e., the party responsible for operating the lined facility.
1.2.10 Project Manager
The Project Manager is the official representative of the Owner. In this manual the term Project Manager shall apply equally
to Construction Coordinator: i.e., the individual in charge of coordination of field activities.
1.3 Meetings and Visits
To guarantee a high degree of quality during installation, open channels of communication are essential. To the end, meetings are
critical.
1.3.1 Pre-Construction Meeting
Following the completion of the design, plans, and specifications for the project, a pre-construction meeting may be held. This
meeting should include all parties involved, including the Owner, the Installer, the Soil Quality Assurance Consultant, the
Design Engineer, and the Project Manager.
Welder start-up and

basic operation
Detail drawings
1.2.8 Geosynthetic Quality Assurance Laboratory

The Geosynthetic Quality Assurance Laboratory is a party responsible for conducting tests on samples of geosynthetics.
The purpose of this meeting is to begin planning for coordination of tasks, anticipate any problems which might cause
difficulties and delays in construction, and above all, present the Geosynthetic Quality Assurance Plan to all parties involved.
It is very important that the rules regarding testing, repair, etc., be known and accepted by all.
Appendix
This meeting should include (but not be limited to) all of the following activities:
Communicate to all parties any relevant documents.
Review critical design details of the project. If a panel layout drawing is required by the specifications it should be reviewed
at this meeting (panel layouts are tentative and may be revised by the Installers site manager with the approval of the field
engineer to suit field conditions at the time of installation).
Review the Geosynthetic Quality Assurance Manual and make any appropriate modifications.
Make any appropriate modifications to the design criteria, plans, and specifications so that the fulfillment of all design
specifications or performance standards can be determined through the implementation of the site specific addendum.
Reach a consensus on the quality control procedures, especially on methods of determining acceptability of the lining
system.
Assign responsibilities of each party; depending on the number of seaming crews and on the type of seaming equipment.
INTRODUCTION
Introduction
Organization Flow Chart
Manufacturing and
delivery
Raw material from supplier
Laboratory Q.C.
Rejected
Accepted
Installation
Sheet Production
Plant Q.C.
Details of welding
systems
Rejected
Accepted
Shipped for installation

Detail drawings
Field installation
Site daily test weld

(field testing)
Accepted
Rejected
Recalibrate equipment
Welder start-up and

basic operation
Proceed with welding
Accepted
Vacuum/Pressure testing
Repair
Defects
Accepted
Repair
Defects
Visual Inspection
Field tested
1 sample (per quantity)
Accepted
Reparative
action to seam
Appendix
Introduction
INTRODUCTION
Establish lines of authority and communication.
Prepare a time schedule for all operations (See section 3.2.2.2).
Any other site specific items pertinent to the lining installation.
Manufacturing and
delivery
1.3.2 Progress Meetings

A daily progress meeting shall be held between the Earthwork Manager, the Installer, the Project Manager, and any other
concerned parties. This meeting shall discuss current progress. Any matter requiring action which is raised in this meeting
shall be reported to the appropriate parties in writing.
Appendix
Welder start-up and

basic operation
Detail drawings
Details of welding
systems
Installation
1.3.3 Manufacturing Plant Visits

A geomembrane manufacturing plant visit may be carried out by a representative of the Owner or his designated alternate if he
so chooses.
MANUFACTURING AND DELIVERY

Introduction
Sinotech
GEOSYNTHETICS
2.1 Manufacturing
For HDPE:
Density (ASTM D1505 or ASTM D792): >0.935 prior to the addition of carbon black.
Melt Flow Index (ASTM D1238, Condition 190/2.16): 0.05 - 0.3g/10 minutes.
Installation
For LLDPE:
Density (ASTM D1505 or ASTM D792): 0.89 - 0.91 prior to the addition of carbon black.
Quality control testing shall be carried out by Sinotech to demonstrate that the product meets this specification.
The Owner or Owners Representative shall verify that:

The property values certified by Sinotech meet all of the specifications; and the measurement of properties by Sinotech are
properly documented, and that the test methods are acceptable.
2.2.1 Transportation and Handling

Transportation of the geomembrane will be performed by Sinotech through an independent shipping/trucking firm, or other
party as agreed upon by the Owner. If the geomembrane arrives on site prior to Sinotech project personnel, the customer is
responsible for off-loading. The geomembrane should be placed on a smooth well drained surface, free of rocks or any other
protrusions which may damage the material. No special covering is necessary for the geomembrane.
Any welding rod delivered to the site prior to arrival of the geomembrane should be kept covered and dry or placed in a storage
facility.
Appendix
Upon arrival at the site, Sinotech shall conduct a surface observation of all rolls for defects and for damage. This inspection
shall be conducted without unrolling the rolls unless defects or damages are found or suspected. Sinotech shall indicate any
damage to the Project Manager.
The following should be verified prior to off-loading of the geomembrane:

Handling equipment used on the site is adequate and does not pose any risk of damage to the geomembrane.
Personnel will handle the geomembrane with care.
Welder start-up and

basic operation
2.2 Delivery
2.1.3 Rolls
After receipt of material, Sinotech shall provide the Project Manager with one quality control certificate for every two rolls of
geomembrane provided. The quality control certificate shall be signed by a responsible party. The quality control certificate
shall include the following:
Roll numbers and identification.
Results of quality control tests. As a minimum, geomembrane results shall be given for thickness, tensile strength, and tear
resistance, evaluated in accordance with ASTM test methods approved by the Designer.
Detail drawings
2.1.2 Geomembrane Manufacturing

Sinotech shall provide the Project Manager/Owner with the following:
A properties sheet including, at a minimum, all specified properties, measured using test methods indicated in the
specifications or equivalent.
Details of welding
systems
Prior to project completion, Sinotech shall provide the Project Manager with the following information:
The origin (resin suppliers name, resin production plant), identification (brand name, number), and production date of the
resin.
A copy of the quality control certificate issued by the resin supplier noting results of density and melt flow index.
Reports on the tests conducted by Sinotech to verify the quality of the resin used to manufacture the geomembrane rolls
assigned to the considered facility [these tests should include density (ASTM D1505 or ASTM D792) and melt flow index
(ASTM D1238, Condition 190/2.16)].
Reports on tests conducted by Sinotech to verify the quality of the sheet.
Manufacturing and
delivery
2.1.1 Geomembrane Raw Material

The raw material shall be first grade polyethylene resin containing no more than 2% clean recycled polymer by weight, and
meeting the following specifications:
Introduction
MANUFACTURING AND DELIVERY
Appendix
Welder start-up and

basic operation
Detail drawings
Details of welding
systems
Installation
Manufacturing and
delivery
2.2.2 Storage
The Project Manager shall provide storage space in a location (or several locations) such that on-site transportation and
handling are minimized. Storage space should be protected from theft, vandalism, passage of vehicles, and be adjacent to the
area to be lined.
INSTALLATION
Introduction
Sinotech
GEOSYNTHETICS
If the anchor trench is excavated in clay susceptible to desiccation, no more than the amount of trench required for the
geomembrane to be anchored in one day shall be excavated (unless otherwise specified) to minimize desiccation potential of
the anchor trench clay soils.
Manufacturing and
delivery
3.1 Anchor Trench Systems

All anchor trench systems shall be excavated by the Earthworks Contractor (unless otherwise specified) to the lines and widths
shown on the design drawings, prior to geomembrane placement.
Slightly rounded corners shall be provided in the trench where the geomembrane adjoins the trench so as to avoid sharp bends
in the geomembrane. No large rocks or clay lumps shall be allowed to underlie the geomembrane in the anchor trench.
3.2.1 Field Panel Identification

A field panel is the unit area of geomembrane which is to be seamed in the field; i.e., a field panel is a roll or a portion of roll cut in
the field.
3.2.2 Field Panel Placement

3.2.2.1 Location
Field panels are to be located by the Sinotech Field Supervisor in a manner consistent with the specifications and best
suited to the existing site conditions.
Sinotech shall record the identification code, location, and date of installation of each geomembrane field panel. Daily
progress reports will be submitted to the Project Manager for forwarding on to the Engineer (Owner) on a daily basis.
Appendix
3.2.2.4 Method of Placement

Sinotech shall verify the following:
Any equipment used does not damage the geomembrane by handling, trafficking, excessive heat, leakage of
hydrocarbons, or other means.
The prepared surface underlying the geomembrane has not deteriorated since previous acceptance and is still
3.2.2.3 Weather Conditions

Welding shall not take place during any precipitation, in the presence of excessive moisture, blowing dust, or in the
presence of excessive winds (unless wind barriers are provided). In addition, welding shall not take place in an area of
ponded water.
Welder start-up and

basic operation
3.2.2.2 Installation Schedule

Field panels are placed one at a time, and each field panel is seamed immediately after its placement (in order to
minimize the number of unseamed field panels)
At the time of installation, the Sinotech Field Supervisor shall give each field panel an identification code (number or letternumber). This identification code shall be agreed upon by the Project Manager. This field panel identification code shall be as
simple and logical as possible.
Detail drawings
Subgrade Preparation Recommendations

No liner shall be placed on surfaces not previously found acceptable by Sinotechs supervisor or his agent.
No sharp stones or other hard objects that could penetrate the liner shall be present in the top 25 mm of the surfaces to be
covered.
Surfaces to be lined shall be smooth and free of all rocks, sharp stones, sticks, roots, sharp objects, or debris of any kind.
The surface should provide a firm, unyielding foundation for the geomembrane with no sudden, sharp or abrupt changes or
break in grade.
Details of welding
systems
3.2 Geosynthetic Placement

Immediately prior to installation of the designed geomembrane liner, the surface shall be observed by Sinotech and the Owner or the
Owners Representative. The decision to repair cracks, if any, shall be made only by the Project Manager. The subgrade shall be
walked by Sinotech and the Project Manager for joint approval. Sinotech will sign acceptance of the surface condition of the
subgrade. The integrity of the underlying soil is the responsibility of the Owner/Earthworks Contractor. Please note Figure 5 for an
example of the Pre-start Site Inspection Certificate of Acceptance.
Installation
Backfilling of the anchor trench shall be conducted in accordance with Section 3.5.
Introduction
INSTALLATION
acceptable immediately prior to geosynthetic placement.
Any geosynthetic elements immediately underlying the geomembrane are clean and free of debris.
All personnel working on the geomembrane do not smoke, wear damaging shoes, or engage in other activities which
could damage the geomembrane.

The method used to unroll the panels does not cause scratches or crimps in the geomembrane and does not damage
Manufacturing and
delivery
the supporting soil.

The method used to place the panels minimizes wrinkles (especially differential wrinkles between adjacent panels).
Adequate temporary loading and/or anchoring (e.g., sand bags, tires), not likely to damage the geomembrane, has
been placed to prevent uplift by the wind [in case of high winds, continuous loading, (e.g., by adjacent sand bags, soil)
is recommended along edges of the panels to minimize risk of wind flow under the panels].
Direct contact with the geomembrane is minimized [i.e., the geomembrane(s) are protected by geotextiles, extra
geomembrane, or other suitable materials in the areas where excessive traffic may be expected].
3.2.2.5 Damage
Sinotech shall inspect each geomembrane after placement and geomembrane prior to seaming for damage. Sinotech
shall advise the Project Manager which geomembrane or portion of geomembrane should be repaired or accepted.
Damaged geomembrane or portions of damaged geomembrane which have been rejected shall be marked and their
removal from the work area recorded by Sinotech. Repairs to the geomembrane shall be made according to procedures
described in Section 3.4.
3.3 Field Seaming
3.3.1 Seam Layout
In general, seams should be oriented parallel to the line of maximum slope; i.e., oriented along, not across, the slope. In
corners and odd-shaped geometric locations, the number of seams should be minimized. No horizontal seam should be less
than 1.5 meters from the toe of the slope or areas of potential stress concentrations unless otherwise authorized. When full roll
lengths do not extend past the toe of the slope, panel ends may be seamed providing the panel end is cut at an angle greater
than 45 to minimize seam stress.
Detail drawings
Details of welding
systems
Installation
Sinotech shall inform the Project Manager if the above conditions are not fulfilled.
A seam numbering system compatible with a panel numbering system shall be agreed upon at the Pre-Construction Meeting.
3.3.1.2 Polyethylene pipe sleeves shall be used for pipe sleeves penetrating through the lined area. When the pipe
composition is polyethylene, the sleeve should be extrusion welded directly to the pipe if space permits. For dissimilar
materials, the sleeve should be fastened by mechanical means and sealant applied between the pipe and the sleeve.
Welder start-up and

basic operation
3.3.1.1 Field joints shall be made by overlapping adjacent sheets approximately 75 mm for extrusion welding and 100 mm for
hot wedge welding.
The extrusion welding apparatus shall be equipped with gauges giving the temperature of the apparatus at the nozzle and the
extruder barrel.
3.3.2 Seaming Equipment and Products

The approval methods for field seaming are extrusion welding and hot wedge welding. Proposed alternate methods shall be
documented and submitted to the Owner or his representative for his approval.
The fusion welding apparatus must be an automated vehicular mounted device which produces a double seam with an
enclosed space or solid seam on thin thickness material as specified.
The fusion welding apparatus shall be equipped with gauges giving the applicable temperature.
Sinotech shall verify the following:
Equipment used for seaming is not likely to damage the geomembrane.
The extrusion welder is purged prior to beginning a seam until all heat-degraded extrudate has been removed from the
barrel.
The electric generator is placed on a smooth base such that no damage occurs to the geomembrane.
Buffing shall be completed no more than one hour prior to extrusion welding (buffing is not necessary for hot wedge
welding).
Appendix
A smooth insulating plate or fabric is placed beneath the hot welding apparatus after usage.
The geomembrane is protected from damage in heavily trafficked areas.
10
INSTALLATION
Introduction
3.3.3 Seam Preparation

Sinotech will verify the following:
Prior to seaming, the seam area is clean and free of moisture, dust, debris of any kind, and foreign material.
Seams are aligned with the fewest possible number of wrinkles and fishmouths.
3.3.4 Weather Conditions for Seaming
The normally required weather conditions for seaming are as follows:
The high temperature limit for welding is the temperature at which the well-being of the crew becomes uncertain.
Unless authorized in writing by the Project Manager, no seaming shall be attempted at ambient temperatures below -15C.
The colder the weather, the slower the welding speeds possible for effective welding.
In all cases, the geomembrane shall be dry and protected from wind. Sinotech shall verify that the weather conditions are
fulfilled and will advise the Project Manager if they are not. The Project Manager shall then decide if the installation shall be
stopped or postponed.
Manufacturing and
delivery
Cold Weather Seaming of Polyethylene Liners

Cold weather welding restrictions exist because problems associated with hot air seaming techniques have been mistakenly
applied to extrusion welds. The extrusion weld, however, has been successfully employed in cold weather on several dozen
job sites. With the assistance of preheating the sheet, the weld can be applied as low as -21C. Both the extrusion weld and
the hot wedge weld are able to overcome cold weather welding restrictions because of their unique designs.
Installation
The extrusion welder is capable of continuously monitoring and controlling the temperatures of the extrudate and the zone of
contact for independence of environmental conditions. To control the molten bead temperature accurately and to ensure no
fluctuation out of the predetermined range the machine has:
An over capacity heater band on the extruder.
An extra over capacity heater band on the nozzle.
A separate proportional temperature controller for each heater band.
The nozzle thermocouple positioned approximately 3 mm from the end of the nozzle which rides on the sheet.
Detail drawings
Destructive testing results are documented from a cold weather installment where the welding temperature were known not to
exceed -12C. The failure rates compare quite favorably with summertime work and indicate that the cold weather conditions
did not imply bad welds for the welding system.
The trial seam sample shall be approximately 1 meter long by 30 cm wide (after seaming) with the seam centered lengthwise.
Seam overlap shall be nominally 100 mm; 75 mm minimum.
11
Appendix
Two adjoining specimens 25 mm wide, shall be cut from the trial seam sample by the installer. The specimens shall be tested
respectively in shear and peel using a field tensiometer, and they should not fail in the seam. If the additional specimen fails,
the entire operation shall be repeated. The seaming apparatus and seamer shall not be accepted and shall not be used for
seaming until the deficiencies are corrected and two consecutive successful full trial welds are achieved.
3.3.5 Trial Seams

Trial seams shall be made on fragment pieces of geomembrane liner to verify that seaming conditions are adequate. Such
trial seams shall be made at the beginning of each seaming period (start of day, midday, and anytime equipment is turned off
and allowed to cool down) for each seaming apparatus used. Trial seams shall be made under the same conditions as actual
seams.
Welder start-up and

basic operation
But to guarantee quality welding in cold weather, the following procedures are recommended for welds:
The sheet should be preheated before welding any time crystals are present in the weld path.
When strong winds are present, a shield of some sort should be set in place to prevent large convection heat losses from the
welding fan during seaming.
Test welds should always be prepared and tested before seaming in order to gauge appropriate welding conditions.
The hot wedge welder lifts the sheet slightly to minimize the effects of subcooling from a frozen sub-base. In addition, the hot
wedge welder comes equipped with a hot air blower attached to the welder which automatically preheats the sheet in the path
of the hot wedge. Temperature controls can be adjusted to guarantee full integrated welding as demonstrated by peel testing.
Details of welding
systems
Extrusion welds are not solely temperature dependent. It combines pressure, extrudate, and mixing action in addition to
temperature, to bond the liner together. The mixing action means that convective heat transfer takes place in addition to
conductive heat transfer. Overall heat transfer if thus improved and sensitivity to ambient temperature is dramatically
reduced.
Introduction
INSTALLATION
Manufacturing and
delivery
3.3.6 General Seaming Procedure

Unless otherwise specified, the general seaming procedure used by Sinotech shall be as follows:
The rolls of membrane shall be overlapped by approximately 100 mm for fusion welding and 75 mm for extrusion welding.
Fishmouths or wrinkles at the seam overlaps shall be cut along the ridge of the wrinkle in order to achieve a flat overlap.
The cut fishmouths or wrinkles shall be seamed and any portion where the overlap is inadequate shall then be patched with
an oval or round patch of the same geomembrane extending a minimum of 150 mm beyond the cut in all directions.
Seaming shall extend up the panels and well into the anchor trench.
All cross seams are to be extrusion welded where they intersect. The top flap of membrane is removed in the area to be
extrusion welded and the weld area is ground parallel to the seam prior to welding.
For fusion welding on wet or muddy subgrade, a movable protective layer of plastic may be required to be placed directly
below the overlapped membranes being seamed. This is to prevent any moisture buildup between sheets to be welded
and/or to provide consistent rate of speed for the wedge welding device.
Installation
3.3.7 Nondestructive Seam Continuity Testing
Details of welding
systems
3.3.7.1 Concept
Sinotech shall nondestructively test all field seams over their full length using a vacuum test unit, air pressure testing, or
other approved method. Vacuum testing is described in Section 3.3.7.2 and air pressure testing is described in Section
3.3.7.3. The purpose of nondestructive tests are to check the continuity of the seams. It does not provide information on
seam strength. Continuity testing shall be carried out as the seaming work progresses, not at the completion of all field
testing.
Detail drawings
3.3.7.2 Vacuum Testing

The equipment shall be comprised of the following:
A vacuum box assembly consisting of a rigid housing, a transparent viewing window, a soft neoprene gasket attached
to the bottom, port hole or valve assembly, and a gauge to indicate chamber vacuum.
A steel vacuum tank and pump assembly equipped with a pressure controller and pipe connections.
A rubber pressure/vacuum hose with fittings and connections.
A bucket and wide brush, mop or spray assembly.
A soapy solution.
Welder start-up and

basic operation
The following procedures shall be followed:

Energize the vacuum pump and reduce the tank pressure to approximately 5 psi (10 of Hg).
Wet a strip of geomembrane approximately 30 cm by 120 cm with the soapy solution.
Place the box over the wetted area.
Close the bleed valve and open the vacuum valve.
Ensure that a leak tight seal is created.
For a period of approximately 5 to 10 seconds, examine the geomembrane through the viewing window for the
presence of soap bubbles.
If no bubbles appear after 10 to 15 seconds, close the vacuum valve and open the bleed valve, move the box over the
next adjoining area with a minimum 75 mm overlap, and repeat the process.
All areas where soap bubbles appear shall be marked and repaired in accordance with Section 3.4.
Vacuum tested seams are recorded on Daily Progress Reports.
3.3.7.3 Pressure Test Specifications for Hot Wedge Welds
Test Pressure (after 5 minutes) psi (max.)
Min.
Max.
Drop Allowed
0.75
24
30
3 psi
1.00
24
30
3 psi
1.50
27
30
3 psi
2.00
27
30
3 psi
2.50 & thicker
30
32
3 psi
Appendix
Membrane thickness (mm)
12
INSTALLATION
3.3.8.2 Location and Frequency

The owner and/or owners representative shall select locations where seam samples will be cut.
All holes in the geomembrane resulting from destructive sampling shall be immediately repaired in accordance with
repair procedures as described in Section 3.4. The continuity of the new seams in the repaired area shall be tested in
accordance with Section 3.3.7.
3.3.8.4 Size of Samples
At a given sampling location, two types of samples shall be taken by the Installer.
Final determination of the sample sizes shall be made at the Pre-Construction Meeting.
3.3.8.5 Field Testing
The two 25 mm wide strips, mentioned in Section 3.3.8.4 shall be tested in the field for peel and shear and shall not fail in
the seam. If any field test sample fails to pass, then the procedure outlined in 3.3.8.7 shall be followed.
13
Appendix
Electric or hand tensiometer testing in the field is to be carried out. The following procedure is followed:
If the initial sample coupon test passes a film tear bond, the sample qualifies for further testing to obtain quantitative
If both sample coupons pass the field test described in Section 3.3.8.5, a sample shall be cut between the two coupons,
this sample shall be cut into three parts and distributed as follows:
One portion to the Installer for testing, 50 cm x 30 cm.
One portion for Geosynthetic Quality Assurance Laboratory testing if applicable, 30 cm x 30 cm.
One portion to the Owner for archive storage, 30 cm x 30 cm.
Welder start-up and

basic operation
First, two sample coupons for field testing should be taken. Each of these sample coupons shall be 25 mm wide by 30
cm long with the seam centered parallel to the length. The distance between these two samples shall be 1 meter.
3.3.8.3 Sampling Procedures

Samples shall be cut by Sinotech as the seaming progresses in order to have test results before the geomembrane is
covered by another material. Sinotech shall:
Cut samples.
Assign a number to each sample which is to be based upon seam and field panel numbers, and mark it accordingly.
Record sample location on daily report.
Detail drawings
These locations shall be established as follows:

A frequency shall be agreed upon by Sinotech and the Project Manager at the Pre-Construction Meeting. Unless
otherwise specified, destructive samples should be pulled at intervals of 1 sample for every 150 linear meters of weld.
The seaming technicians shall not be informed in advance of the locations where the seam samples will be taken.
Details of welding
systems
3.3.8.1 Concept
Destructive seam tests shall be performed at random selected locations. The purpose of these tests is to check that
welds are fully integrated with each other and to evaluate seam strength. Seam strength testing shall be done as the
seaming work progresses, not at the completion of all field seaming.
Installation
3.3.8 Destructive Testing
Manufacturing and
delivery
The following procedures shall be followed:

Seal both ends of the seam to be tested.
Insert needle or other approved pressure feed device into the tunnel created by the fusion weld.
Energize the air pump to a pressure between 25 to 30 psi, close valve, and sustain pressure for roughly 5 minutes.
If loss of pressure exceeds above listed values, or does not stabilize, locate faulty area and repair in accordance with
Section 3.4.
Remove needle or other approved pressure feed device and seal.
Pressure tested seams are recorded on Daily Progress Reports.
Introduction
3.3.7.4 Air Pressure Testing (for Hot Wedge Welds)

The equipment shall be comprised of the following:
An air pump (manual or motor driven) equipped with a pressure gauge capable of generating and sustaining a
pressure between 25 and 30 psi.
A rubber hose with fittings and connections.
A sharp hollow needle, or other approved pressure feed device.
Introduction
INSTALLATION
results.
If it fails the seam should be repaired in accordance with Section 3.4.
Manufacturing and
delivery
Destructive Testing of Seams

Destructive testing of seams is very important because it provides the only direct evaluation of seam strength and
bonding efficiency which indicates seam durability.
Destructive testing involves two techniques:
1. Shear testing - this test method applies a tensile stress from the top sheet through the weld and into the bottom sheet.
2. Peel testing - this test method peels the top sheet back against the overlapped edge of the bottom sheet in order to
observe how separation occurs. The peel test indicates whether or not the sheets are continuously and homogeneously
connected through the seam.
Installation
Sinotechs standard procedure is as follows:

If there is a failure in either peel or shear then a total of five coupons are tested. If more than one coupon fails then the
sample fails. This is a modified ASTM method. The ASTM methods that are D4437, D413, and D638 can all apply.
Details of welding
systems
Reason for Pass/Fail Criteria

The FTB requirement is very important. With a fully integrated, continuous connection through the seam, no weld
bead/sheet or sheet/sheet interface exists. Such an interface might be separated by absorbed chemicals, causing
failure of the seam.
In addition to the FTB criterion, a minimum stress level is specified. This is important in order to protect against legitimate
tearing of a thin portion of polymer in the weld (as might occur if the weld is off center).
Detail drawings
The minimum stress levels are necessarily lower than tensile yield strengths of the parent sheet because of the different
configuration of the test specimens during destructive testing. Bending moments come into play along with straight
tensile stresses especially as the sheets are bent back in peel. These bending moments depend on the shape of the
welds which vary even within the same welding technique. The minimum stress values are based on the average
performance values of passed weld specimens tested in the laboratory.
3.3.8.6 Procedures for Destructive Test Failure
The following procedures shall apply whenever a sample fails a destructive test. Sinotech has two options:
1. Reconstruct the seam between any two passed test locations.

2. Trace the welding path to an intermediate location [3 meters max. from the point of the failed test in each direction] and
take a small sample coupon for an additional field test at each location. If these additional samples pass the field test,
then full samples are taken. If these samples pass the test, then the seam is reconstructed between these locations. If
either sample fails, then the process is repeated to establish the zone in which the seam should be reconstructed.
All accepted seams must be bounded by two locations from which samples passing destructive tests have been taken.
3.4 Defects and Repairs

3.4.1 Identification
All seams and non-seam areas of the geomembrane shall be examined by Sinotech for identification of defects, holes, blisters,
undispersed raw materials and any sign of contamination by foreign matter.
3.4.1.1 Defective/damaged material shall be identified via a deficiency report, either separately or on the Daily Report
form. Actions taken to resolve or correct the problem will also be recorded on a similar form.
Welder start-up and

basic operation
Sinotech shall document all actions taken in conjunction with destructive test failures; e.g., capping of failed seam area.
3.4.1.2 Defects, holes, blisters, undispersed raw materials, signs of contamination by foreign matter, unacceptable
welds in geomembranes and other unsatisfactory conditions will be identified on the Daily Report form. The
repair/corrective action to fix the problem will also be recorded on a similar form.
Appendix
3.4.2 Evaluation
Each suspect location both in seam and non-seam shall be nondestructively tested using the methods described in Section
3.3.7 as appropriate. Each location which fails the non-destructive testing shall be marked by Sinotech and repaired. Work
shall not proceed with any materials which will cover locations which have been repaired until laboratory test results with
14
INSTALLATION
Introduction
passing values are available.

3.4.3 Repair Procedures
Patching: used to repair large holes, tears, and contamination by foreign minister.
Buffing and re-welding: used to repair small sections of extruded seams.
Spot welding or seaming: used to repair pinholes, or other minor localized flaws.
Capping: used to repair areas of inadequate seams which have an exposed edge.
3.6 Lining System Acceptance

The geosynthetic lining system shall be accepted when:
The installation of all materials are deployed and welded.
Verification of the adequacy of all seams and repairs including associated testing is complete.
Appendix
15
Welder start-up and

basic operation
3.7 Soils in Contact with the Geomembrane

Important points for quality assurance of soils in contact with geomembranes include:
A geotextile or other cushion provided by the designer may be installed between angular aggregate and the geomembrane.
Equipment used for placing soil shall not be driven directly on the geomembrane.
A minimum thickness of 30 cm of soil is recommended between a light dozer (such as CAT D-3 or wide track caterpillar D-6 or
lighter) and the geomembrane.
In heavily trafficked areas such as access ramps, soil thickness should be at least 60 to 90 cm.
Soil/earth cover on top of geomembrane.
Placement of soils, sand, or other types of earth cover on top of the liner shall not be performed until all destructive and
nondestructive testing has been performed and accepted.
Placement should be performed to minimize wrinkles. Equipment operators should be briefed on method of placement and
affects to thermal expansion and contraction of the liner.
Material placed on top of the liner should be back-dumped on liner and, in order to avoid the formation of wrinkles, efforts should be
made to load the soil so that it comes down on top of the liner rather than being pushed across the sheet. This is done by 10 using a
front end loader to place soil ahead of spreading soil cover, and 20 spreading soil by building a mound at the edge of soil, then
pushing soil up over the mound causing to come down on the liner.
If a wrinkle forms, every effort should be made to walk the wrinkle out.
Minor folding over the wrinkles is acceptable providing an even transition occurs at the tail of the wrinkle. If excessive stress points
are crated at the tail of the wrinkle, the wrinkle should be cut out and repaired per Section 3.4.
Since backfilling the anchor trench can affect material bridging at toe of slope, consideration should be given to backfill the liner at its
most contracted state; preferable during the cool of the morning or extended period of overcast skies. Care shall be taken when
backfilling the trenches to prevent any damage to the geosynthetics.
Detail drawings
3.5 Backfilling of Anchor Trench

The anchor trench, if any, shall be adequately drained by Owner/Earthwork Contractor to prevent ponding or otherwise softening of
the adjacent soils while the trench is open. The anchor trench shall be backfilled by the Earthwork Contractor or as outlined in the
specifications and bid documents.
Details of welding
systems
3.4.3.2 Geomembrane Verification of Repairs

Each repair shall be nondestructively tested using the methods described in Section 3.3.7 as appropriate. Repairs
which pass the nondestructive test shall be taken as an indication of an adequate repair. Failed tests indicate that the
repair shall be redone and retested until a passing test result is obtained.
Installation
In addition, the following provisions shall be satisfied:

Surfaces of the geomembrane which are to be repaired shall be abraded no more than one hour prior to repair.
All surfaces must be clean and dry at the time of repair.
All seaming equipment used in repairing procedures must be approved.
The repair procedures, materials, and techniques shall be approved in advance of the specific repair by the Project
Manager and Sinotech.
Patches or caps shall extend at least 150 mm beyond the edge of the defect, and all corners of patches shall be
rounded with a radius of at least 75 mm.
Manufacturing and
delivery
3.4.3.1 Geomembrane Repair Procedures

Any portion of the geomembrane failing a destructive or nondestructive test shall be repaired. Several procedures exist
for the repair of these areas. The final decision as to the appropriate repair procedure shall be agreed upon between the
Project Manager and Sinotech. The procedures available include:
Introduction
INSTALLATION
Figure 2.5.3A
Locus-of-break codes for dielectric-welder or solvent-welded seams in unreinforced FMLs tested for seam strength in shear and peel modes.
Manufacturing and
delivery
Schematic of Untested Specimen

Weld
Top sheet
Direction
of peel
Bottom sheet
Installation
Types of Breaks
Locus-of-Break Code
Break Description
Classification
CL
Break in sheeting at clamp

edge
Note 2
BRK
Break in sheeting
FTB
SE
Break at seam edge
FTB
AD-BRK
Break in sheeting after

some adhesion failure
between the sheets
FTB
AD
Failure in adhesion
between the sheets
Non-FTB
Appendix
Welder start-up and

basic operation
Detail drawings
Details of welding
systems
Clamp
Notes
1. FTB = Film - Tear Bond.
2. Acceptance of CL - type breaks may depend on whether test values meet a minimum specification value. In general, though, a CL - type break should be
considered a no test. If specimens for a particular sample break consistently at the clamp edge, changes in the testing procedure should be considered, e.g.
changing the clamp face, using a dumbbell - type specimen.
16
INSTALLATION
Introduction
Figure 2.5.3C
Locus-of-break codes for fillet-extrusion weld seams in semi-crystalline FMLs tested for seam strength in shear and peel modes.
Schematic of Untested Specimen
Manufacturing and
delivery
Outer area
Bead
Buffed area
Hot tack
(delamination)
Types of Breaks
AD2
Failure in adhesion.
Non-FTB
AD-WLD
Break through the fillet. Breaks through the fillet range

from breaks starting at the edge of the top sheet to breaks
through the fillet after some adhesion failure between the
fillet and the bottom sheet.
Non-FTB
SE1
Break at seam edge in the bottom sheet. Specimens may

break anywhere from the bead/outer area edge to the
outer area/buffed area edge. (Application to shear only).
FTB
SE2
Break at seam edge in the top sheet. Specimens may break

anywhere from bead/outer area edge to the outer
area/buffed area edge.
FTB
SE3
Break at seam edge in the bottom sheet.

(Applicable to peel only).
FTB
BRK1
Break in the bottom sheeting. A B in parentheses

following the code means the specimen broke in the
buffed area. (Applicable to shear only)
FTB
BRK2
Break in the top sheeting. A B in parentheses following

the code means the specimen broke in the buffed area.
FTB
AD-BRK
Break in the bottom sheeting after some adhesion failure

between the fillet and the bottom sheet.
(Applicable to peel only)
FTB
HT
Break at the edge of the hot tack for specimens which

could not be delaminated in the hot tack.
No Test
Non-FTB
Welder start-up and

basic operation
Failure in adhesion. Specimens may also delaminate under

the bead and break through the thin extruded material in
the outer areas.
AD1
Detail drawings
Classification
Details of welding
systems
Break Description
Installation
Locus-of-Break Code
17
Appendix
Notes
1. FTB = Film - Tear Bond.
2. Acceptance of AD-WLD breaks may depend on whether test values meet a minimum specification value and not on classification as a FTB or non-FTB break.
Introduction
DETAILS OF WELDING SYSTEM
Sinotech
GEOSYNTHETICS
4.1 Details of Hot Wedge Welding System

Manufacturing and
delivery
4.1.1 FML Preparation

4.1.1.1 Note that this document assumes that the proper FML has been brought to its exact plan position for final
installation seaming.
4.1.1.2 The two FMLs to be joined must be properly positioned such that approximately three (3) inches (75 mm) of
overlap exists.
Installation
4.1.1.3 If the overlap is insufficient, lift the FML up to allow air beneath it and float it into proper position. Avoid dragging
FML sheets, particularly when they are on rough soil subgrades since scratches in the material can create various stress
points of different depths and orientations.
Details of welding
systems
4.1.1.5 There generally will excessive slack in the FMLs depending on the ambient temperature, length of time of FML
will be exposed, etc.
Detail drawings
4.1.1.4 There can be no excessive undulations (waves) along the seams during the seaming operation due to problems
in slack adjustment. When this occurs, with the upper sheet having more slack than the lower one, it often leads to the
undesirable formation of fishmouths which must be trimmed, laid flat, and reseamed via a patch.
4.1.1.8 No seaming is allowed during rain or snow, unless the seam is covered with an enclosure.
4.1.1.6 The sheet which are overlapped for seaming must be clean.
4.1.1.7 The sheets which are overlapped for seaming must be completely free of moisture in the area of the seam. Air
blowers are usually preferred over rags because sufficient dry rags are usually not available to keep the FML dry enough
to be suitable for seaming.
4.1.1.9 The soil surface beneath the FMLs cannot be saturated because the heat of seaming will draw the water into the
region to be joined. Ponded water on the soils surface beneath the FML is never allowed.
4.1.1.10 The soil surface beneath the FMLs cannot be saturated because the heat of seaming will thaw the frost allowing
water to be drawn into the region to be joined. The seaming, however, can be accomplished with rub sheets of FML
directly under seam edges.
4.1.1.11 Ambient temperatures for seaming should be above freezing (i.e., 32F / 0C). However, seam welding
temperatures below 32F (0C) can be accomplished as stated in Item L.
Welder start-up and

basic operation
4.1.1.12 For cold weather seaming, it may be advisable to preheat the sheets with a hot air blower, to use a shield of
some sort to prevent heat losses during seaming, and to make numerous test welds in order to determine appropriate
seaming conditions (e.g. equipment temperatures should be set higher and seaming rates slowed down during cold
weather seaming).
4.1.2 Equipment Preparation
4.1.2.1 A working and properly functioning small electric generator must be available within close proximity of the
seaming region and with adequate extension cords to complete the entire seam. The generator must be rubber tire, or
placed on a smooth plate such that it is completely stable so that no damage can occur to the FML> Fuel (gasoline or
diesel) for the generator must be stored off the FML.
4.1.2.2 A hot wedge seaming device is a completely self contained system known as a hot shoe.
4.1.2.3 As the hot wedge method is one of melting the opposing surfaces of the two FMLs to be joined, no grinding of
sheets in necessary, nor allowed.
4.1.2.4 Tracking of the FML sheets as done in extrudate fillet seaming is not needed.
Appendix
4.1.2.5 The hot wedge itself, or anvil, should be inspected to see that it is uniform and reasonably tapered. Various
types are currently available. Some are smooth surfaced while others have patterned ridges in the direction of the seam.
18

Introduction
The taper dimensions vary according to different types of machines. The major point for inspection is that no sharp edges
should exist where FML sheet surfaces must pass.
4.1.2.6 Knurled rollers for applying pressure on the sheets and driving the device, follow the wedge. They should be
inspected for sharp surfaces.
Manufacturing and
delivery
4.1.2.7 If a dual, or split hot wedge seam is being made, the recessed space for the air track should be examined. See the
following sketches:
Installation
Dual (Split) Wedge
4.1.2.9 The front part of the seaming device should be inspected for sharp corners and irregular details which may
damage the FMLs.
Detail drawings
4.1.2.8 As the FML sheet materials pass through the machine, they must come in contact with the wedge in order to heat
the material properly. Hot wedge welding machines are equipped with pressure shoes which assure contact between the
FML sheet and the wedge as the material passes through the machine. Once the welding machine has been set up for a
particular FML thickness, further field adjustments are not required. The wedge has an adjustment that is actually a
stopping device to keep the hot shoe, or anvil from being pulled into the nip/drive rollers, especially when material is not
going through the machine. Serious damage will occur to the FML sheets if the wedge gets pulled through the nip/drive
rollers.
Details of welding
systems
Single Wedge
4.1.2.10 Temperature controllers on the wedge device should be checked periodically.
4.1.3.1 The hot wedge system is properly positioned for the making of a dual (split) seam.
4.1.3.3 Temperature setting will vary according to FML thickness being installed. In general, the sheet surface
temperature as it passes through the nip/drive rollers is about 30F (15C) lower than the wedge itself.
19
Appendix
4.1.3.5 Power for the drive motor should be off when positioning the machine to make a seam. Manually place the
machine into the overlapped sheet of material.. The sheets should be guided between the idlers and wedge, and into the
drive/nip rollers. This procedure is only possible when starting with two sheets. When starting a weld in the middle of two
sheets, the material must be loaded from the sides. The machine is to be picked up a few inches, loading the bottom
sheet first, and then the top sheet. As soon as the nip rollers are engaged and the wedge is in position, the power to the
drive motor should be turned on. Once the sheets are between the nip rollers, they shall be engaged immediately,
4.1.3.4 Ambient temperatures such as clouds, moisture, and hot sun will require the temperature settings of the wedge to
vary. A test strip of at least 5 feet (1.5 Meters) in length should be run before welding begins, which will enable the
operator to find the proper settings for the particular conditions that day. See Article 3.3.5. Depending upon the records to
be kept, one might record a number of different temperatures. For example, the temperature of the hot anvil, the
temperature of the sheet after seaming, the temperature of the sheet away from the seaming area, and the ambient
temperature.
Welder start-up and

basic operation
4.1.3.2 The principle of the hot wedge is that both surfaces to be fused come into intimate contact with the hot wedge, or
anvil. The wedge lifts up both layers of FML off the subgrade and fusion is brought about by compressing the two melted
surfaces together, causing an intermingling of the polymers at a pressure of approximately on hundred pounds per
square inch. The hot anvil itself reduces the surface tension of the viscous polymer sheets and acts as a scraper/mixer,
followed closely by the nip roller which squeezes the two FMLs together.
4.1.3 Actual Seaming Process
Introduction

Upper flexible
membrane liner
Manufacturing and
delivery
Nip/drive rollers
Hot wedge
or anvil
Installation
Lower flexible
membrane liner
otherwise a melt-through will occur within a few seconds. The hot wedge should be moved into position and locked.
Details of welding
systems
4.1.3.6 It is necessary that the operator keep constant visual contact with the temperature controls, as well as the
completed seam coming out of the machine. Occasional adjustments of the temperature will be necessary to maintain a
consistent weld. Visual inspection and constant hand testing by the peel method or another method as cited in Article
3.3.8.2 is also recommended.
4.1.3.7 On some soils, the wedge tends to bulldoze into the ground as it travels. This causes soil to enter the weld
making the seam weak and unacceptable. To overcome this, it is recommended that the operator take some of the
weight off the front of the machine by lifting it slightly. Alternatively, some type of base for the machine to travel on could
be provided. Strips of geotextile or geomembrane have proven effective to prevent this bulldozing effect.
Detail drawings
4.1.4 After Seaming

4.1.4.1 A smooth insulating plate or heat insulating fabric is to be placed beneath the hot welding apparatus after usage.
4.1.4.2 A slight amount of squeeze-out or flashing is a good indicator that the proper temperatures were achieved. It
signifies a proper seam in that some of the melted polymer was laterally extruded out of the seam zone. The pressure
should be decreased until only a minimal amount of hot melt is squeezing out.
4.1.4.3 For FMLs of 40 mil thickness and less, a long, low wave-length pattern in one direction of the seam on its top
surface is indicative of a proper weld. If the wave peaks become too close together, the machine speed should be
increased until a satisfactory pattern is present. The absence of this wavelength pattern indicates that the machine
speed should be decreased. FMLs of 40 mil in thickness and less require considerable visual inspection. There will be
no wavy pattern for FMLs greater than 40 mil in thickness due to the inherent stiffness of the thicker material.
Welder start-up and

basic operation
4.1.4.4 Nip/drive roller marks will always show on the surface. Their depth, however, should be visually observable, but
just barely evident to the touch.
4.1.4.5 The hot wedge device has only a few adjustments that can be made, but it is very important that they be checked
daily. Cleaning of machine should be done at least daily.
4.1.5 Peel Test for Hot Wedge Weld Seam

This test is the most severe test that a seam can be subjected to. The peel test is the greatest proof that a seam will have the
strength to last the life of the flexible membrane liner (FML). The mechanical procedures of the peel test are as follows:
4.1.5.1 Procedure
Seam sample cut approximately one (1) inch (25 mm) wide by approximately six (6) inches (150 mm) long.
Only the inner weld track is peeled apart in this destructive test. The outer track (directly at the sheet edge) is for the
purpose of air pressure testing capabilities.

Clamp bottom tabs into the testing machine (Field Tensometer or Lab Instrom), turn on the machine and pull the seam
(See Detail A).

Appendix
All testing of destructive samples of fusion seam will be in accordance with ASTM D 413 and ASTM D 638.
Passing results for a seam are determined to be FTB per the chart titled, Destructive Testing of Dual Hot Wedge.
20

Introduction
Two (2) clamps
Manufacturing and
delivery
Inner weld track

Air pressure test channel
Installation
Top sheet
Outer weld track
Bottom sheet
4.2 Seam Testing Procedure
4.2.2 Test Procedure

4.2.2.1 Seal one end of the seam by applying heat to the end of the seam, via hand leister, until "flow temperature" is
achieved.
4.2.2.2 Clamp off end using hand vise gripper.

4.2.2.3 A pressure gauge/needle assembly is inserted into void or air chamber.
4.2.2.4 Air pressure is then applied into the air chamber with the use of an air pump per the following schedule:
Initial Pressure Schedule (Field Testing)

Maximum PSI
0.75
24
30
1.00
24
30
1.50
27
30
2.00
27
30
2.50*
30
32
Minimum PSI
Welder start-up and

basic operation
Detail drawings
4.2.1 General
This unique automatic seaming machine creates two distinct seams. These two seams are separated by a void or air space.
This seam design is intentional for two primary reasons. First, it allows a very positive test for leak integrity, and second, the
double weld seam offers both a primary and a secondary seal for the seam.
Details of welding
systems
Tab adequate for testing

outer weld track
*Sinotech manufactures a thicker HDPE membrane on special order. Seaming and field testing procedures are on file upon request.
4.2.2.5 After initial start of air pressure, the air should be allowed to reach ambient liner temperature.
21
Appendix
4.2.2.6 Pressure test FML seam according the initial pressure test schedule. Hold test for five minutes. If no pressure
drop is greater than the maximum allowable pressure drop, the seam is judged leak free.
Introduction

Maximum Allowable Pressure Drop
Manufacturing and
delivery
Installation
Details of welding
systems
0.75
3 psi
1.00
3 psi
1.50
3 psi
2.00
3 psi
2.50
3 psi
Notes:
1. Sinotech manufactures a thicker HDPE membrane on special order. Seaming and field testing procedures are on file upon
request by client.
2. At all times heat sealing the end of the seam the operator should insure that the void or air channel is free of obstruction. This
is obtained by allowing air pressure to travel freely to the opposite end of the pressure gage/needle assembly.
4.3 Field Seam Failure

Should failure occur through excessive leak down over the scheduled time period, check both ends of the seam to ensure proper seal
and retest. Should failure reoccur, check the top fusion seam by applying a constant flow of air pressure to void or air channel. Mix a
strong solution of liquid detergent and water and apply an ample amount to the top fusion weld. Any failure of leak will be indicated by
continuous bubbles appearing.
If no failure appears in top fusion seam area, check systematically by isolating random sections of the seam. This should be
accomplished in one hundred and fifty linear foot sections of seam. Then retest each section by pressure testing until the leak is
located. Repair failed seam area by extrusion welding the outside edge of the top fusion weld between areas of failure. Then vacuum
test repair seam area. All repairs in accordance with Sinotech's Quality Assurance/Quality Control Manual.
4.4 Details of Extrusion Welding System
4.4.1 Introduction
The Hot Wedge Welding System is the primary seaming system for FML installation and the Extrusion Welding System is
utilized for repairs and detail work. The Extrusion Welding System produces a seam quality equal to the Hot Wedge Weld and
has the advantage that all welds are applied on top of the FML which allows its use at "T" intersections and in irregular seam
areas such as pipe boots.
Detail drawings
Field Test (after 5 minutes)
When tested in peel, the numerical values for weld strength of an extrusion weld will be slightly lower than for hot wedge welds
(see paragraph 3.3.8.6, page 16 of this manual). The lower value is the result of the weld bead on top of the liner changing the
geometry of the weld bead on top of the liner changing the geometry of the test and not an indication of inferior weld quality.
Welder start-up and

basic operation
4.4.2 FML Preparation

4.4.2.1 FML preparation is the same as described for the hot wedge weld in Section 1 of Appendix D.
4.4.3 Equipment Preparation
4.4.3.1 A working and properly functioning small electric generator must be available within close proximity of the
seaming region and with adequate extension cords to complete the entire seam. The generator must be rubber tired, or
placed on a smooth plate such that it is completely stable so that no damage can occur to the FML. Fuel (gasoline or
diesel) for the generator must be stored off the FML.
4.4.3.2 The extrusion welder is a completely self contained system which requires no adjustment after it has been initially
set up for a particular FML thickness.
4.4.3.3 An initial inspection of the extrusion welder should be made before the first heat up to confirm that the electrical
cords, insulation, and covers are in good condition and that the welding nozzle is correct for the FML to be seamed.
Appendix
4.4.3.4 The welding machine should be connected to a proper power supply and heated to the correct welding
temperature for the FML to be seamed.
22

Introduction
4.4.3.5 After the unit has reached correct operating temperature, clean, dry welding rod should be inserted and the unit
operated for several minutes to confirm that temperature controllers are operating properly and that the welding rod feed
system and rotating tips are operating properly.
4.4.3.6 The flow of extrudate from the test run will force the rotating tip to the outermost position and these can now be
checked for proper setting with depth calipers.
4.4.4 Actual Seaming Process
4.4.4.2 The FML to be extrusion welded must be temporarily bonded to hold the material in place until the extrusion weld
bead cools and attains full strength. This is normally accomplished by performing an automatic or hand hot air tack weld.
Installation
4.4.4.1 FML material to be extrusion welded must have surface oxidation removed by lightly grinding the weld surface
with a 60 to 80 grit disc. The grinding is performed parallel to the seam and controlled such that grinding marks do not
extend more than 0.25 inches outside the area of the weld bead. Grinding should precede the actual welding as closely
as possible but in no case should grinding precede welding by more than one hour. 60 mil or thicker lines should have the
edge of the top sheet beveled by grinding to approximately 45 degree angle.
Manufacturing and
delivery
4.4.3.7 The teflon shoes should be checked for excessive wear and replaced if necessary. The teflon shoes must be
trimmed for proper control of the weld bead configuration.
4.4.4.3 The extrusion welder should be purged of all degraded plastics prior to the start of seaming.
4.4.4.5 All extrusion welds should be non-destructively tested by vacuum testing as described in the QC Manual. Areas
which cannot be non-destructively tested should be capped.
Details of welding
systems
4.4.4.4 The welding operation should be observed to assure that the weld bead is centered over the edge of the top FML
sheet and that the weld bead appearance is smooth and uniform.
4.4.4.6 Destructive tests can be conducted when seam lengths are adequate.
Hazo, H.E. Jr., "Quality Assurance of Geomembrane Used as Linings for Hazardous Waste Containment", Jour, Geotex and
Geomembrane., Vol. 3, No. 4, 1986, pp. 225-248
Koerner, R.M., Designing with Geosynthetics, 2nd Edition, Prentice Hall Publ. Co., Englewood Cliffs, NJ, 1990.
Matrecon, Inc. "Lining of Waste Containment and Other Impoundment Facilities", EPA/600/2-88/052, September 1988
Rosen, S.L., Fundamental Principles of Polymer Materials, J. Wiley and Sons, Inc. New York, 1982
Koerner, G.R. and Bove, J.A., "Construction Quality Assurance of HDPE Geomembrane Installations", Proc. Geosynthetics '89, San
Diego, CA IFA1, pp. 70-83.
Detail drawings
4.5 References
"Construction Quality Assurance for Hazardous Waste Land Disposal Facilities", EPA/530/SW-86-031, October 1986
Welder start-up and

basic operation
Appendix
23
Manufacturing and
delivery
Introduction
DETAILS
Geomembrane
Installation
Fused material
Edge of track
Details of welding
systems
Squeeze-out
Air channel
Detail drawings
Weld track
Welder start-up and

basic operation
Notes:
1. Double fusion hot wedge welding is the most common seaming technique used to weld
polyethylene together.
2. Air pressure or vacuum testing are the two methods to test a seam made by a double fusion
hot wedge welding.
3. Refer to Sinotechs Installation Quality Control Manual for the specific method.
This drawing is the property of Sinotech Environmental Technologies Limited and may not be copied or reproduced in
any way without the written permission of Sinotech. This drawing contains information believed to be correct, but
which is subject to change without notice. The details are offered as a guide for consideration to assist engineers with
their designs. However, Sinotech assumes no liablity in connection with the use of this information.
Detail title
Typical Double Fusion Hot Wedge Weld
Sinotech
Appendix
GEOSYNTHETICS
Drawn by
Checked by
Date
02 August 2006
24
Revised
Drawing number
CMC
Date
001A
DETAILS
Introduction
Manufacturing and
delivery
Geomembrane
Installation
Extrudate weld
Details of welding
systems
Detail drawings
10 cm
(maximum)
Notes:
1. Refer to Sinotechs Installation Quality Control Manual for the specific destructive and nondestructive test methods.
2. All sheet 1.5 mm and above needs to be beveled.
Welder start-up and

basic operation
Detail title
Typical Extrusion Weld
Sinotech
GEOSYNTHETICS
Drawn by
Checked by
Revised
Drawing number
CMC
Date
001B
Appendix
Date
02 August 2006
25
Manufacturing and
delivery
Introduction
DETAILS
30 cm
90 cm
Installation
Top of berm
60 cm
Geomembrane
Details of welding
systems
1
Varies
Detail drawings
Backfill
Welder start-up and

basic operation
Notes:
1. The above dimensions are suggested minimum standards: actual distances to be
determined based on site specific criteria such as soil conditions, material thickness, climatic
conditions, slope angle, and slope length as determined by the design engineer.
2. Backfill should be sufficiently compacted to prevent line pullout.
Detail title
Typical Anchor Trench
Sinotech
Appendix
GEOSYNTHETICS
Drawn by
Checked by
Date
19 November 2006
26
Revised
Drawing number
CMC
Date
002A
DETAILS
Introduction
10 mm S.S. banding
HDPE pipe boot
Manufacturing and
delivery
Notes:
1. All concrete surfaces to be steel
trowel finished with round and
smooth edges.
2. Slopes steeper than 3:1 should be
avoided.
Neoprene gasket
Pipe wall
Installation
Detail A-1
Geomembrane
Details of welding
systems
Extrusion weld
Geotextile
Detail A-1
Detail drawings
Caulking
15 cm thick
reinforced
concrete slab
1
Varies
Welder start-up and

basic operation
Pipe
Detail title
Pipe Boot (Single Liner System)
Sinotech
GEOSYNTHETICS
Drawn by
Checked by
Revised
Drawing number
CMC
Date
007
Appendix
Date
27 February 2007
27
Introduction
DETAILS
38 mm x 6.4mm
S.S. batten with 9.5 mm dia. x
89 mm long anchor bolt
HDPE
pipe boot
Manufacturing and
delivery
13 mm S.S.
banding
3.8 cm x 3.2 cm
thick S.S. flat bar
Neoprene
gasket
Installation
Pipe wall
50 mm x 6.4 mm
thick neoprene double
gasket continuous
Detail A-1
Notes:
smooth edges.
avoided.
Geomembrane
Details of welding
systems
Detail A-2
Extrusion weld (typ.)
Detail A-1
Detail A-2
Caulking
10
(m cm
in.
)
Detail drawings
Geotextile
15 cm thick
reinforced
concrete slab
Welder start-up and

basic operation
Varies
Pipe
Geotextile
10
(m cm
in.
)
Detail title
Pipe Boot (with Batten Attachment)
Sinotech
Appendix
GEOSYNTHETICS
Drawn by
Checked by
Date
30 November 2006
28
Revised
Drawing number
CMC
Date
008A
DETAILS
Extrusion weld
13 mm S.S.
banding
Geomembrane
Introduction
HDPE
pipe boot
Manufacturing and
delivery
Neoprene
gasket
Pipe wall
Concrete lock
Installation
Detail A-1
Detail A-2
Geomembrane
Details of welding
systems
Notes:
smooth edges.
avoided.
Extrusion weld (typ.)

Detail A-1
Geotextile
Detail drawings
Detail A-2
Caulking
10
(m cm
in.
)
15 cm thick
reinforced
concrete slab
1
Varies
Welder start-up and

basic operation
Pipe
10
(m cm
in.
)
Detail title
Pipe Boot (with Concrete Lock)
Sinotech
GEOSYNTHETICS
Drawn by
Checked by
Revised
Drawing number
CMC
Date
009
Appendix
Date
27 November 2006
29
Introduction
DETAILS
Extrusion weld
Manufacturing and
delivery
Notes:
smooth edges.
avoided.
Geomembrane
Installation
Concrete lock
Detail A
Details of welding
systems
Geomembrane
Detail A
mi 45
n. cm
all
sid
e
Detail drawings
10
(m cm
in.
)
15
(m cm
in.
)
1
Inlet/outlet pipe
Welder start-up and

basic operation
Varies
10
(m cm
in.
)
15 cm thick reinforced
concrete slab
Detail title
Pipe Seal (with Concrete Lock)
Sinotech
Appendix
GEOSYNTHETICS
Drawn by
Checked by
Date
01 November 2006
30
Revised
Drawing number
CMC
Date
010
DETAILS
Introduction
Manufacturing and
delivery
1 cm anchor bolt
Washer
6 mm x 50 mm
steel batten
Installation
Nut
Geomembrane
Details of welding
systems
6 mm x 50 mm closed
cell neoprene sponge
Detail drawings
Neoprene adhesive

Welder start-up and
basic operation
Detail title
Single Liner Anchoring to Concrete
Sinotech
GEOSYNTHETICS
Drawn by
Checked by
Revised
Drawing number
CMC
Date
011
Appendix
Date
11 March 2006
31
Introduction
DETAILS
Manufacturing and
delivery
10 mm x 90 mm lg. S.S. wedge

type anchor bolt with
nut and washer 1 mm O.C.
Three (3) layers of
50 mm x 6 mm thick neoprene
triple gasket continuous
40 mm x 6 mm thick
S.S. flat bar
Geomembrane
Detail drawings
Details of welding
systems
Installation
Caulking
10 cm
minimum
Welder start-up and

basic operation
Notes:
1. Concrete surfaces at attachment locations to be steel trowel finished or ground smooth
prior to installation.
2. Avoid vertical wall attachment whenever possible.
3. When using geotextile or drainage net, do not terminate beneath the batten bar.
Detail title
Typical Concrete Attachment (Double Liner System)
Sinotech
Appendix
GEOSYNTHETICS
Drawn by
Checked by
Date
12 March 2006
32
Revised
Drawing number
CMC
Date
012
DETAILS
Introduction
Manufacturing and
delivery
6 mm x 50 mm closed cell
neoprene sponge
6 mm x 12 mm batten
Installation
Washer
Details of welding
systems
Welded stud bolt

10 mm x 30 mm
Steel wall
Nut
Detail drawings
Neoprene adhesive
Geomembrane
Welder start-up and

basic operation
Detail title
Single Liner Anchoring to Steel
Sinotech
GEOSYNTHETICS
Drawn by
Checked by
Revised
Drawing number
CMC
Date
014
Appendix
Date
30 November 2006
33
Manufacturing and
delivery
Introduction
DETAILS
DETAILS
Extrusion weld
all around
Installation
Neoprene adhesive
and sponge
HDPE patch
Details of welding
systems
Geotextile
Detail drawings
10 mm x 100 mm
304 stainless
steel anchor bolt
with round and
slotted head
S.S. plate 5 mm x 50 mm
x 100 mm with
6 mm - 12 mm radius
on exposed edges
Wall anchors attached

to concrete spaced
equally vertically and
2 meters center to
center horizontal
Concrete wall
Welder start-up and

basic operation
1.5 mm Geomembrane
Detail title
Typical Concrete Attachment
Sinotech
Appendix
GEOSYNTHETICS
Drawn by
Checked by
Date
30 November 2006
34
Revised
Drawing number
CMC
Date
015
DETAILS
Introduction
Manufacturing and
delivery
Geomembrane
Geonet
Concrete wall
Installation
Clamp / 2 places
(side by side)
HDPE pipe
Details of welding
systems
Boot end extrusion

welded to pipe
(HDPE pipes only)
Detail drawings
Pipe boot
(vacuum formed)
Extrusion weld
6mm x 100 mm
neoprene sponge
ring
Rub sheet between

pipe boot & clamp
Welder start-up and

basic operation
Detail title
Typical Boot Attachment
Sinotech
GEOSYNTHETICS
Drawn by
Checked by
Revised
Drawing number
CMC
Date
031
Appendix
Date
01 December 2006
35
Manufacturing and
delivery
Introduction
DETAILS
DETAILS
Installation
Neoprene sponge and

silicone seal
Pipe
Steel clamp
Geomembrane
Welder start-up and

basic operation
Detail drawings
Details of welding
systems
Fillet weld
Detail title
Fabricated HDPE Clamped Penetration Boot
Sinotech
Appendix
GEOSYNTHETICS
Drawn by
Checked by
Date
01 December 2006
36
Revised
Drawing number
CMC
Date
033
DETAILS
Top of slope
2A
Introduction
1A
9A 10A
Toe of slope
21D
8A
3A
4A
20D
5A
6A
7A
5B
17D
6B
16D
7B
15D
8B
14D
9B
13D
10B
11B
1E
2E
3E
4E
5E
6E
7E
8E
9E 10E 11E 12E
10D
13B
9D
14B
8D
15B
7D
16B
6D
17B
5D
18B
4D
19B
7C
6C
5C
Detail drawings
12B
Details of welding
systems
11D
20B
4C
3C
8C
2D
Installation
4B
18D
3D
2B
3B
19D
12D
Manufacturing and
delivery
1B
22D
21B
1D
22B
2C
10C 9C
1C
Welder start-up and

basic operation
Notes:
1. Panel lengths include slope gain and anchor trench.
2. Minimum distance from toe of slope for tie-in is 130 cm.
3. 15 cm minimum overlap at double fusion wedge weld seams.
4. All field seams to be perpendicular to slope.
5. Panel installation to proceed from highest floor elevation to lowest.
Detail title
Panel Layout
Sinotech
GEOSYNTHETICS
Drawn by
Checked by
Revised
Drawing number
CMC
Date
042
Appendix
Date
01 December 2006
37
Manufacturing and
delivery
Introduction
PRE-START SITE INSPECTION
Sinotech
GEOSYNTHETICS
6.1 Pre-Construction Site Inspection

The Liner installation area particularly the subgrade and other civil works associated with the liner installation should be inspected
prior to commencing deployment.
6.1.1 Subgrade Surface
6.1.1.1 The Subgrade Surface should be smooth and free of all rocks, sharp stones, sticks, roots, sharp objects, or
debris of any kind.
Installation
6.1.1.2 The surface should provide a firm, unyielding foundation for the membrane with no sudden, sharp, or Abrupt
changes or break in grade.
6.1.1.3 There should be no standing water or mud on the Subgrade Surface.
6.1.2 Anchor Trench
The Anchor Trench Dimensions should be checked and the trench should also be checked for ponded water.
Details of welding
systems
6.1.3 Liner Penetrations

Check that all pipe penetrations, and other structures requiring mechanical fastening have been properly constructed.
6.1.4 Material Storage Area
The storage area should be stored on a smooth surface free of rocks or other objects which may damage the material.
6.1.4.1 Liner materials should be stored on a smooth surface free of rocks or other objects which may damage the
material.
6.1.5 Installation Area Accessibility

Access to the Installation Area should be checked to determine if there are any limitations which may
influence decisions regarding equipment selection, starting point, installation schedule, or deployment
methods.
6.2 Panel Layout and Deployment Plan
The area to be lined should be accurately measured and a site drawing or sketch produced, detailing the panel
and seam locations or layout. (Refer to Section 7 for a panel layout example)
6.2.1 Scrap
The panel layout should be planned to minimize scrap, as well as, the total length of weld required to complete installation.
6.2.2 Prefabrication
The practicality of prefabricated liner sections should be considered.
Welder start-up and

basic operation
Detail drawings
6.1.4.2 Geotextiles should be protected from ultraviolet light and precipitation prior to installation.
6.2.3 Panel and Seam Orientation

In general, liner panels should be orientated parallel to the line of maximum slope, not across the slope.
6.2.3.1 Panels can be deployed horizontally across the slope only when the total length of material required to extend
through the anchor trench, down the slope and beyond the toe of slope, is less than the material roll width, (i.e., a 1m 2:1
slope with a 60 cm anchor trench).
6.2.3.2 Panels should never be oriented in a way that would require seams to be welded horizontally across the slope.
6.2.3.3 Seams should never be located at the top of the slope.
Appendix
6.2.4 Liner Contraction and Compensators

Local weather patterns should be taken into consideration to determine if compensators will be required to prevent excessive
contraction stresses and liner lifting or bridging at toe of slopes.
38

Introduction
6.2.4.1 Compensators are wrinkles or folds of extra material which are built into the liner to allow for future contraction of
the liner.
6.3 Installation Schedule
After completion of the panel layout sketch, an installation schedule should be produced. Daily and/or weekly goals should be set for
the completion of specific areas, and the completion of specific tasks such as mechanical attachments, scrap removal, etc.
Manufacturing and
delivery
6.4 Daily Reports

A detailed report of liner installation activities should be produced on a daily basis. At a minimum the report should contain details of
panels deployed, seams welded, and seams quality control tested. (For a daily report example refer to Section 9.)
6.4.1 Liner Panels
As deployment progresses, liner panels should be assigned an identification number. This number along with the roll number,
material thickness, material type, and panel measurements should be recorded in the daily report.
Installation
6.4.2 Seams
As the installation progresses all seams should be assigned an identification number. This number along with the seam length,
and welding machine serial number and operators name should be recorded in the daily reports.
6.4.3 Quality Control Testing
All destructive and non-destructive tests should also be recorded in the daily report.
Details of welding
systems
6.5 As-Built Drawings

As-Built Drawings should be produced as the installation progresses and updated daily. (Refer to Section 8 for an example of an AsBuilt Drawing).
6.5.1 The As-Built Drawings should document all seam, liner penetration, repair, trench, and sample location.
6.5.2 All panel numbers, roll numbers, and seam numbers should also be documented on the As-Built Drawing.
Detail drawings
6.5.3 As-Built Drawings should be drawn to scale or have accurate dimensions so that the area of installed liner can be
accurately calculated.
6.6 Deployment
6.6.2 Machinery
Front end loaders are commonly used to deploy liner materials, although other types of equipment such as all-terrain forklifts
or cranes can be used.
6.6.3 Spreader and Axle Bars

Spreader Bars are attached to a front-end loader or other machinery used with the axle bar to deploy liner materials.
6.6.3.1 Spreader Bars are typically constructed from steel I-beams or steel pipe. Axle Bars are constructed of thick
walled steel pipe approximately 15 cm. in diameter.
6.6.4 Deployment Methods

Liner materials can be deployed by several methods. Ensure that whichever method is used does not damage the liner, and
that the material is not folded, creased, or crimped during deployment.
39
Appendix
6.6.4.1 The most commonly used method of deployment is to unroll the material using a spreader and axle bar by placing
the roll on the ground and driving the machine.
6.6.3.2 Spreader and Axle Bars should be a minimum 1m longer than the roll width and be capable of supporting a full roll
of material.
Welder start-up and

basic operation
6.6.2.1 Equipment used to deploy 6.86 meter rolls should be capable of lifting and transporting a minimum of 2,000 kg.
6.6.1 Weather Conditions

Deployment should not be attempted during periods of high wind, precipitation, or when ambient conditions prohibit successful
welding operations.
Manufacturing and
delivery
Introduction
Detail drawings
Details of welding
systems
Installation
6.6.4.3 The roll with axle bar can also be placed on a set of stationary stands and material pulled off the roll. This method
can be used for small projects when only small amounts of material are required.
6.6.5 Material Inspection

The liner panels should be inspected immediately after deployment and any damage or manufacturing flaws found should be
marked for repair.
6.6.6 Overlap and Panel Alignment
After deploying and inspecting each panel, overlap it with the previous laid panel by 10 cm.
6.6.6.1 The panels can be marked with a crayon, 10 cm. from the edge, to simplify alignment.
Welder start-up and

basic operation
6.6.6.2 Vise-grip sheet metal clamps, or similar tools which will not damage the liner, should be used to pull the panels
into place and to align the overlaps.
6.6.7 Welding
Seams should be welded immediately after the panels are aligned so as to reduce the possibility of problems caused by
expansion and contraction of the liner or weather related problems such as wind damage.
6.6.8 Ballast Bags

Sandbags should be used to ballast the liner against uplift by wind.
6.6.8.1 Sandbags weighing 15 - 15 kg. should be placed no more than 60 cm. apart on all liner edges to prevent wind
damage.
6.6.8.2 During extremely windy conditions sandbags should be more closely spaced.
Appendix
6.6.9 Anchor Trench Backfilling

The Anchor Trench should not be completely backfilled immediately after deployment. Only the minimum amount of fill
required to hold the liner or sandbags, should be placed in the trench until the liner has fully contracted.
40

Introduction
If the Trench is completely backfilled when the liner is expanded it will cause unnecessary stress and bridging at the toe of the
slope when the liner contracts.
6.7 Geotextiles, Geonets, and Geogrids
6.8 Extrusion Welder Start-Up and Basic Operation
Manufacturing and
delivery
6.7.1 Geotextile, Geonet, and Geogrid Deployment

Geotextiles, Geonets and Geogrids can be deployed using the same methods used to deploy liner material or can be placed
on the ground and unrolled using manpower.
6.8.1 Check the machine for loose bolts, damaged parts, frayed wires, etc.
6.8.2 Check the voltage before connecting the machine to the power supply.
Installation
6.8.2.1 For 220/240 volt machine min. volts 220 / max. volts 250
6.8.2.2 For 120 volt machine min. volts 120 / max. volts 130.
6.8.3 Check that the drive motor switch is in the "off" position.
6.8.5 The machine should now be "on". Check the temperature controllers for a digital display. Do not start the drive motor until
the nozzle and extruder temperatures have reached at least 200 degrees C.
Details of welding
systems
6.8.4 Connect the machine to the power source and depress the circuit breaker to the "on" position. (See figure 2).
6.8.6 Check that the nozzle is clean and the correct size for the material to be welded. (See set-up instructions).
Detail drawings
6.8.7 Check that the rotating tips are set correctly. (See set-up instructions).
6.8.8 Check that the Teflon shoes are not worn and are trimmed properly. (See set-up instructions).
6.8.9 Check that the sight is not bent and is in line with the nozzle step.
6.8.11 With the drive motor running, insert the welding rod into the feed block.
6.8.10 When the nozzle and extruder temperatures reach their set points, start the drive motor and check the voltage at the
machine while the motor is running.
Welder start-up and

basic operation
Appendix
41
Introduction
WELDER START-UP AND BASIC OPERATION
Sinotech
GEOSYNTHETICS
7.1 Extrusion Welder Power Requirements

Manufacturing and
delivery
7.1.1 Generator Requirements

A. 120 Volt Extruders
Voltage Minimum - 120 Volts
Voltage Maximum - 130 Volts
Installation
B. 220 - 240 Vol Extruders

Voltage Minimum - 220 Volts
Voltage Maximum - 25 Volts
50 - 60 Hertz
5 KVA Minimum
7.1.1.1 A 5 KVA minimum allows for the simultaneous use of the extruder and grinder or hot air blower.
Details of welding
systems
Note that generator output ratings are based on output at sea level with normal air temperatures. At high elevations or in
extremely high air temperatures, generator output can be reduced significantly. It is advisable when working in these
conditions to use a generator rated at an output of 15% -50% more than would be required normally.
7.1.1.2 Check the voltage at the end of the extension cord with the machine running to ensure there is not excessive loss
of voltage.
7.1.1.3 Use the splitter cable to check the voltage at the machine.
7.1.2.1 Extension cables should not exceed 75 meters in length.

7.1.2.2 Failure to use proper sized extension cables will cause excessive voltage loss during machine operation,
resulting in poor performance and machine damage.
7.2 Extrusion Welder Setting Requirements
Welder start-up and

basic operation
Detail drawings
7.1.2 Extension Cables

Extension cables must have three conductors of copper wire with a cross sectional area a minimum of 2.5m.
0.75
1.00
1.50
2.00
2.50
3.00
Upper tip protrusion (mm)
0.25
0.50
0.50
0.50
0.50
Nozzle head step (mm)
1.00
1.00
2.00
2.00
2.50
Lower protrusion (mm)
0.25
0.50
0.50
0.50
0.50
Nozzle temperature controller setting (C)

- HDS and HDT
- LLS and LLT
250
230
250
240
265
255
275
260
285
265
295
-
Extruder temperature controller setting (C)

- HDS and HDT
- LLS and LLT
205
205
240
210
255
215
260
220
265
225
Note: Check the tip settings when the machine is hot and after extrudate has been run through the machine for at least one
(1) minute.
7.3 Extrusion Welding Operations

Appendix
7.3.1 Start and check the machine as detailed in the basic operations and daily check list section.
42

Introduction
7.3.2 Before beginning welding operations check that the seaming area is clean and free of moisture. Also check that the
subgrade under the liner is smooth and level.
7.3.3 Overlap the liner by a minimum of 10 cm and tack with hot air. When tacking ensure that the liner surface remains smooth
and flat. Do not allow the material to become molten and deformed.
7.3.4 Using a 10,000 rpm 4 1/2 angle grinder fitted with an 80 grit aluminum oxide disc, grind the surface of the liner material a
maximum of 15 mm on each side of the seam. The orientation of the grinding marks should be perpendicular to the seam rather
than parallel.
Manufacturing and
delivery
7.3.3.1 When welding liner materials 1.5 mm or thicker chamfer the edge of the top sheet by approximately 45 degrees
prior to tacking. (See Detail SIN-D 001B)
7.3.4.1 Take care not to grind an excessively wide path or to grind too deep.
7.3.4.3 Ensure that the length of the seam is ground completely as the weld will not bond in any areas that are not ground
properly.
7.3.4.5 After grinding ensure that the seam remains clean and dry. If an area of seam becomes dirty after grinding do not
attempt to clean it with rags or hands, this can be deposit additional dirt into the grind. The area should be reground.
Details of welding
systems
7.3.4.4 Grinding must take place immediately prior to welding, any areas left unwelded for extended periods after
grinding must be reground before welding can be resumed.
Installation
7.3.4.2 Check that the grinding disc is not worn and that the grit is not clogged with plastic.
7.3.5 Prior to welding, start the extruder drive and purge the machine of old extrudate, then with a wire brush remove excess
extrudate from the nozzle.
7.3.6.1 Note the step in the nozzle which corresponds to the step created by the overlap of liner material. This determines
the welding direction.
Detail drawings
7.3.6 Place the machine onto the seam and immediately start the drive motor and begin moving the machine forward.
7.3.6.2 The extruder should always be held perpendicular to the liner surface.
7.3.6.2.2
Leaning extruder backward will cause the weld to be too thin and will not allow proper surface action by rotating
tips.
7.3.6.3 The sight pin must be kept parallel to the seam and centered at the edge of the top sheet in order to keep the weld
centered on the seam.
7.3.6.5 During welding operations, ensure that the welding rod remains clean and dry.
7.3.6.6 When stopping, turn the extruder motor off and immediately remove the machine from the liner to prevent the
nozzle from melting the liner.
43
Appendix
7.4 Trial Weld Samples

A trial weld should be welded each day prior to welding operations to ensure that the extruder is functioning properly and the machine
is properly set up for the ambient conditions.
7.3.6.4 To establish the correct welding speed look at the weld behind the machine. If there is excessive flashing the
welding speed should be increased. If the weld appears thin or insufficiently filled out or has gaps in it the speed must be
decreased.
Welder start-up and

basic operation
7.3.6.2.3
Leaning the extruder to the side will cause an excessive build-up of flashing on the opposite side of the weld.
7.3.6.2.1
Leaning the extruder forward will cause the nozzle to dig into or drag on the liner surface.
Introduction

7.4.1 Trial welds should be a least 1 meter in length and should be made of the same material to be welded during welding
operations. They should also be welded in the same ambient conditions that will be experienced during welding operations.
7.4.2 Trial welds should be welded according to the methods described in the welding instructions.
Manufacturing and
delivery
7.4.3 After welding allow the seam to cool, then cut two (2) test strips 10 - 15 mm wide and hand test in peel. The weld should
not peel and there should be a film tearing bond.
7.4.4 Check that the weld is centered on the seam.
7.4.5 If the initial trial weld fails testing, check the temperature settings, the rotating tip protrusion settings, and ensure the
ambient conditions are acceptable for welding. Then produce another trial weld and retest.
7.5 Special Welding Techniques

7.5.1 Continuation of a previous weld
When a weld is re-started, care is needed to avoid capillary leaks where the new weld overlaps the end of the old weld. The
same technique is used for sealing to the end of an old weld.
7.5.1.1 Grind off the end of the old weld by a minimum of 5 cm with an angle grinder, taking care not to grind through the
membrane.
Details of welding
systems
Installation
7.4.6 Do not begin welding operations until a passing trial weld has been produced.
7.5.1.2 Brush the area free from grindings.

7.5.1.3 Weld slowly down the ground edge onto the welded overlap.
Detail drawings
7.5.2 Welding T-Joints
Seam A
Seam B
7.5.2.1 Weld seam "A" through the intersection.
7.5.2.2 Grind weld "A" at the area of intersection removing all flashing.
Welder start-up and

basic operation
7.5.2.3 Weld seam "B" up to the intersection.
7.5.3 Welding Patches

Patches are required:
To repair physical damage (e.g. pinholes).
Where a sample membrane or weld has been removed.
To repair pinholes.
7.5.3.1 Cut an oval patch which will extend beyond the edges of the hole by at least 10 cm in all directions.
7.5.3.2 If welds have to be crossed, grind a dished segment down to the level of the membrane at the crossing points.
7.5.3.3 When patching over wedge welded seams the flap must be removed from the wedge weld in the area of
intersection prior to placing the patch.
7.5.3.4 Using hot air tack weld the patch to the liner.
Appendix
7.5.3.5 Clean and grind the joint as for a normal weld.
44

Introduction
7.5.3.6 Weld half of the patch down, starting on one straight edge and finishing on the other. Allow the weld to cool.
7.5.3.7 Grind both start and finish of the weld and complete the patching.
7.5.4 Welding Over Pinholes
Manufacturing and
delivery
7.5.4.1 Prepare the membrane as for normal welding by wiping the area, then grinding and brushing it clean.
7.5.4.2 Run a weld over the pinhole.
7.6 Additional Notes
7.6.1 Always round corners. Do not try to weld through a 90 degree turn.
7.6.3 Never attempt to "X" or cross a hot weld at T-Joints, as this cuts in and causes pinhole leaks.
Installation
7.6.2 Never run 2 welds side by side when the first weld is still hot. The sliding shoes cut through the first weld causing small pin
holes. Always allow the first weld to cool, then grind it before running the weld next to it.
7.6.4 Do not weld-over-weld-over-weld, etc. The area should be patched.
7.6.6 A board or plank should be used to support the edges of the sheet which have to be welded before placing in the anchor
trench.
Details of welding
systems
7.6.5 When the nozzle starts cutting into the weld, change shoes immediately.
7.6.7 Do not weld over small fishmouth. They must be cut, flattened, and patched.
Detail drawings
Welder start-up and
basic operation
Appendix
45
Manufacturing and
delivery
Introduction
STANDARD SPECIFICATIONS FOR HDPE LINING MATERIAL
Sinotech
GEOSYNTHETICS
8.1 Scope
These specifications describe High Density Polyethylene (HDPE) Lining Membranes. The supply and installation of these materials
shall be in strict accordance with the Engineer's specifications and engineering drawings and subject to the terms and conditions of
the contract.
8.2 Manufacturers Experience
The manufacturer of the lining material described hereunder shall have previously demonstrated his ability to produce this
membrane by having successfully manufactured a minimum of one hundred million square feet (9,290,226 square meters) of similar
liner material for hydraulic lining installations.
Installation
8.3 Lining Material

8.3.1 The new membrane liner shall comprise HDPE material manufactured of new, first-quality products deigned and
manufactured specifically for the purpose of liquid containment in hydraulic structures.
8.3.3 The liner material shall be so produced as to be free of holes, blisters, undispersed raw materials, or any sign of
contamination by foreign matter. Any such defect shall be repaired using the extrusion fusion welding technique in accordance
with the manufacturer's recommendations.
8.3.4 The lining material shall be manufactured a minimum of 22.5 feet (6.86 meters) seamless widths. Labels on the roll shall
identify the thickness, length, and manufacturer's roll number. There shall be no factory seams.
8.3.5 The liner material shall meet the specification values according to the specification sheet for HDPE.
8.4 Factory Quality Control
8.4.1 Raw Material
All compound ingredients of the HDPE materials shall be randomly sampled on delivery to the HDPE manufacturing plant to
ensure compliance with specifications. Tests to be carried out shall include Density ASTM D 1505 and Melt Index ASTM D
1238, Condition E & P.
Detail drawings
Details of welding
systems
8.3.2 The contractor shall, at the time of bidding, submit a certification from the manufacturer of the sheeting, stating that the
sheeting meets physical property requirements for the intended application.
8.4.2 Manufactured Roll Goods

Samples of the production run shall be taken and tested according to ASTM D 638 to ensure that tensile strength at yield break,
elongation at yield and break meet the minimum specifications. A quality control certificate shall be issued with the material.
8.5 Installation
8.5.1 Area Subgrade Preparation
Surfaces to be lined shall be smooth and free of all rocks, stones, sticks, roots, sharp objects, or debris of any kind. The surface
should provide a firm, unyielding foundation for the membrane with no sudden, sharp or abrupt changes or break in grade. No
standing water or excessive moisture shall be allowed. The installation contractor shall certify in writing that the surface on
which the membrane is to be installed is acceptable before commencing work.
Welder start-up and

basic operation
8.4.3 All welding material shall be of a type supplied by the manufacturer.
8.5.2 Contractor Approval

The installation of the HDPE must be done by the manufacturer using the manufacturer's extrusion or hot wedge welding
equipment and installation methods. All supervisors overseeing the liner installation must have ten million square feet of
supervisory liner experience. All field technicians must have over one million square feet of seaming experience.
Appendix
8.5.3 Field Seams

Individual panels of liner material shall be laid out and overlapped by a maximum of four inches (101 millimeters) For extrusion
weld prior to welding or five inches (127 millimeters) for hot wedge weld prior to welding. Extreme care shall be taken by the
installer in the preparation of the areas to be welded. The area to be welded shall be cleaned and prepared according to the
46
STANDARD SPECIFICATIONS FOR HDPE LINING MATERIAL
8.5.5 No "fishmouths" shall be allowed within the seam area. Where "fishmouths" occur, the material shall be cut, overlapped,
and an overlap extrusion weld shall be applied.
Manufacturing and
delivery
8.5.4 The welding equipment used shall be capable of continuously monitoring and controlling the temperature in the zone of
contact where the machine is actually fusing the lining materials so as to ensure that changes in the environmental conditions
will not affect the integrity of the weld.
Introduction
procedures laid down by the material manufacturer. All sheeting shall be welded together by means of integration of the
extrudate bead with the lining material. The composition of the extrudate shall be identical to the lining material, using either
Phillips TR-400 or Chevron 9642, or all sheeting shall be welded together using the hot wedge welding system.
8.6 Field Seam Testing/Quality Control

8.6.1 The installer shall employ on-site physical non-destructive testing on all welds.
8.6.4 The end user company, or his designated representative, reserves the right of access for inspection of any or all phases
of this installation at their expense.
Detail drawings
8.7 Warranty and Guarantee

The manufacturer/installer shall provide a written warranty.
Details of welding
systems
8.6.3 A test weld three (3) feet long (one meter) from each welding machine shall be run each day prior to liner welding and
under the same conditions as exist for the liner welding. The test weld shall be marked with date, ambient temperature, and
welding machine number. Samples of weld 1/4 inch to 1/2 inch (10 mm to 20 mm) wide shall be cut from the test weld and
pulled by hand in peel. The weld should not peel. Seams should exhibit a film tear bond. The weld sample shall be kept for
subsequent testing on laboratory tensiometer equipment in accordance with the applicable ASTM standards. Random weld
samples may be removed from the installed welded sheeting at a frequency to be agreed (e.g. 1/500' of weld).
Installation
8.6.2 A quality control technician shall inspect each seam. Where "fishmouths" occur, the material shall be cut, overlapped,
and an overlap extrusion weld shall be applied.

Welder start-up and
basic operation
Appendix
47
Sinotech Subgrade Surface Acceptance
Job number:
Project location:
Date:
Details of welding
systems
Project name:
I, the undersigned duly authorized representative of Sinotech Environmental Technologies Limited, certify that upon
visual inspection, the subgrade surface described below meets the criteria for the installation of a ____ mm flexible
membrane liner. By signing below, however, Sinotech Environmental Technologies Limited acknowledges no
responsibility for the subgrade design, degree of moisture or compaction, integrity, elevation, or maintenance thereof,
in any way.
Detail drawings
Installation
Manufacturing and
delivery
Introduction
APPENDIX
Approximate size of area:
Sinotech Representative
Owner/Contractor
Inspector
Appendix
Welder start-up and

basic operation
Description of the area:
48
APPENDIX
Introduction
Sinotech Pre-Start Site Inspection

Project
Location
Manufacturing and
delivery
Date
1. Inspected by
Name
Representing
Position
Installation
2. Description of inspected area
Details of welding
systems
Photos enclosed
To follow
3. Remedial work required

Detail drawings
Yes
No
Date
Welder start-up and

basic operation
5. Further inspection required?
4. Date & condition of Sinotech Environmental Technologies Limited start-up
6. Billing for additional inspection/work (Must be accompanied by a Change Order)
Owner/Contractor
Inspector
Appendix
49
50
Description
Total:
Time
Type of
material
m
deployed
m
welded
Welder start-up and

basic operation
Sinotech Daily/Weekly Production Report
Appendix
m
q.c.d
Total:
Hours
Detail drawings
Supervisor
Total
hours
Technician
Total:
Project name
Date
Installation
Hours
Total
hours
Total:
Labor
Superintendent
Sinotech project no.
Details of welding
systems
Hours
Page
Total
hours
of
Total:
Others Hours
Manufacturing and
delivery
Total
hours
Introduction
APPENDIX
4
5
Welder start-up and

basic operation
Project Name:
Sinotech Project No.:
Superintendent:
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Detail drawings
Details of welding
systems
Month:
Installation
Name:
Manufacturing and
delivery
Appendix
51
Introduction
Sinotech Proposed Performance Schedule
APPENDIX
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Sinotech Subgrade Surface Acceptance
Job number:
Project location:
Date:
( ) * +, - . /
01
Project name:
( )* + , 23
I, the undersigned duly authorized representative of Sinotech Environmental Technologies Limited, certify that upon
visual inspection, the subgrade surface described below meets the criteria for the installation of a ____ mm flexible
membrane liner. By signing below, however, Sinotech Environmental Technologies Limited acknowledges no
responsibility for the subgrade design, degree of moisture or compaction, integrity, elevation, or maintenance thereof,
in any way.
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Sinotech Environmental Technologies Limited

Yanyang Zia Road, Northern Industrial Park
Chenyang District, Qingdao 266109
China
^
_@ R
1: 266 10 9
Telephone
+86 532 87961918
0532-87961918
Fax
+86 532 87960616
0532-87960616
&S
E-mail
info@sinotechgeo.com
Website
www.sinotechgeo.com
Sinotech
GEOSYNTHETICS

Installation QAQC Manual

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Sinotech

INSTALLATION QUALITY ASSURANCE MANUAL

Sinotech Environmental Technologies Limited

Welder start-up and

Pre-start site inspection

SINOTECH GEOMEMBRANE INSTALLATION QUALITY ASSURANCE MANUAL

1.1 Terms of Reference

In the context of liner production and installation:

1.1.3 Lining Materials

SINOTECH GEOMEMBRANE INSTALLATION QUALITY ASSURANCE MANUAL

Welder start-up and

1.1.4 Scope of Quality Assurance and Quality Control

Pre-start site inspection

1.2 Parties (refer to the flow chart on the next page)

1.2.3 Resin Supplier

Welder start-up and

Pre-start site inspection

1.2.8 Geosynthetic Quality Assurance Laboratory

SINOTECH GEOMEMBRANE INSTALLATION QUALITY ASSURANCE MANUAL

Organization Flow Chart

Raw material from supplier

Shipped for installation

Site daily test weld

Pre-start site inspection

Welder start-up and

Proceed with welding

SINOTECH GEOMEMBRANE INSTALLATION QUALITY ASSURANCE MANUAL

1.3.2 Progress Meetings

Welder start-up and

Pre-start site inspection

1.3.3 Manufacturing Plant Visits

SINOTECH GEOMEMBRANE INSTALLATION QUALITY ASSURANCE MANUAL

MANUFACTURING AND DELIVERY

The Owner or Owners Representative shall verify that:

2.2.1 Transportation and Handling

The following should be verified prior to off-loading of the geomembrane:

Welder start-up and

Pre-start site inspection

2.1.2 Geomembrane Manufacturing

SINOTECH GEOMEMBRANE INSTALLATION QUALITY ASSURANCE MANUAL

2.1.1 Geomembrane Raw Material

MANUFACTURING AND DELIVERY

Welder start-up and

Pre-start site inspection

SINOTECH GEOMEMBRANE INSTALLATION QUALITY ASSURANCE MANUAL

3.1 Anchor Trench Systems

3.2.1 Field Panel Identification

3.2.2 Field Panel Placement

SINOTECH GEOMEMBRANE INSTALLATION QUALITY ASSURANCE MANUAL

3.2.2.4 Method of Placement

3.2.2.3 Weather Conditions

Welder start-up and

3.2.2.2 Installation Schedule

Pre-start site inspection

Subgrade Preparation Recommendations

3.2 Geosynthetic Placement

could damage the geomembrane.

the supporting soil.

Pre-start site inspection

Welder start-up and

3.3.2 Seaming Equipment and Products

SINOTECH GEOMEMBRANE INSTALLATION QUALITY ASSURANCE MANUAL

3.3.3 Seam Preparation

Cold Weather Seaming of Polyethylene Liners