StudLiner®

PRODUCT

INSTALLATION GUIDELINES

REV. 03.20

SOLMAX.COM
 TABLE OF
CONTENTS

1.0 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.0 TYPICAL PRECAST GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.0 TYPICAL CAST-IN-PLACE GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4.0 SEAM WELDING AND TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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1.0 Introduction:
StudLiner® can be supplied in either sheet form or prefabricated pieces for precast applications. Standard roll
dimensions for StudLiner® are 2.44 m (8 ft) widths and up to 75 m (246 ft) lengths approximately. Rolls may
be precut and fabricated to any size dimension required, or shipped to site in rolls. When material is
received on site it should be placed on a clean smooth surface to prevent damage. Light reflective StudLiner®
should be kept out of direct exposure to sunlight. Solmax can supply thin mil HD liners to act as a temporary
cover.

2.0 TYPICAL PRECAST GUIDELINES

A. Material Handling and Storage
StudLiner® can be supplied in either sheet form or prefabricated pieces for precast applications.
Standard roll dimensions for StudLiner® are 2.44 m (8 ft) widths and up to 75 m (246 ft) lengths
approximately. Rolls may be precut and fabricated to any size dimension required, or shipped to site in
rolls. When material is received on site it should be placed on a clean smooth surface to prevent
damage. Light reflective StudLiner® should be kept out of direct exposure to sunlight. Solmax can
supply thin mil HD liners to act as a temporary cover. Unloading of StudLiner® rolls should be
performed by equipment that will lift the roll from the center core. Rolls should be placed on a firm,
smooth surface free of large, sharp stones.

B. Pipes and Manholes

Precasting of materials is advantageous to most projects. Costs are minimized and quality control is
maximized. Material may be supplied in either precut sheets, or prefabricated tube sleeves. Typical
precast pieces do not require any working or welding of the plastic materials unless sheet materials are
supplied. When prefabricated items are utilized, Materials are shipped from manufacturer ready to be
placed over forms and have concrete applied. In either case before applying liner, the form should be
clean of any defects or protrusions, and any concrete residue which may damage the liner when form
is expanded.

1. Sheet Materials
If bulk material is provided, cut to the proper dimension and wrap the liner around the inner form
and secure using mechanical devices such as banding or wire. Bands should be located in the
interstitial space between studs to prevent crushing or tilting of the embedment studs. It should
not be necessary to cut or remove any of the embedment material in order to accommodate
banding. Seams can be welded prior to placing metal reinforcement cage to prevent migration of
concrete between overlapped longitudinal seams.

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 a. Butt Welding
When butt seaming, the joint should have a maximum gap of 0.2 in. The weld should be made
by applying an extrusion bead to the back of the butt joint or by some other method
acceptable to prevent concrete from migrating between overlapped surfaces. After the forms
have been stripped, a second extrusion weld bead is then applied over the butt joint on the
smooth face of the liner.

b. Overlap with Extrusion Weld

In order to facilitate an overlap weld, it will be necessary to remove the studs on the underlying
portion of the liner that is to be welded. This can be accomplished through the use of a
sharpened chisel and a small hammer. Care should be taken not to damage the parent liner
when removing the studs. The overlap should consist of approximately a 4 in overlap fused
together by an extrusion weld or some other acceptable method to prevent the concrete from
migrating under the overlapped sheet. Once forms are removed the internal overlap should
also be extrusion welded.

2. Prefabricated Materials
a. If the material is provided in prefabricated tubular form, lower the liner over and around the
collapsed inner form. The form should then be expanded until liner is taught over form. It is
necessary to monitor the expansion of the form to avoid over-stressing the liner during this
process as overstressing may lead to unwanted elongation of the liner material.

b. The liner should sit flush with the inner edge of the bell or spigot end of a pipe section.
If needed or desired the liner may extend beyond the opposite end approximately 4 in
depending upon the type of lining joint to be made with the adjoining concrete pipe.
Embedment studs should be removed within the 4 in to produce a smooth layer for overlap
lining joint.

c. Care should be taken when using a vibration method during the pouring of the concrete in
order to avoid damaging the liner. It is important to achieve a tense homogeneous bond
between the concrete, this will ensure the maximum performance of the studded surface of
the Solmax StudLiner®. Once concrete has been poured into the form, standard curing
procedures should be followed.

C. Partial or 270° Installation

If the specifications require that the tube form or pipe be lined only 270° around the perimeter,
Solmax can prefabricate the tube or sheet with 270° of embedment liner and remaining area lined
with smooth sheet. The smooth sheet can be removed after curing to allow for standard operating
procedures of precast form to continue while meeting the specifications. This also provides a
termination point within the liner that is flush and smooth with the concrete pipe itself.

D. Specialty Shapes and Sizes

Solmax can prefabricate any unique system which may be encountered through specifications. Contact
the Solmax Fabrication Department to coordinate dimensions and details. Precast procedures are same
as above.

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3.0 TYPICAL CASE-IN-PLACE GUIDELINES
A. Material Handling and Storage
StudLiner® can be supplied in either roll form or prefabricated panels for critical applications. Standard
roll dimensions for StudLiner® are 2.44 m (8 ft) widths and up to 75 m (246 ft) lengths
approximately. Rolls may be precut and fabricated to any size dimension required, or shipped to
site in rolls. When material is received on site it should be placed on a clean smooth surface to prevent
damage to the liner. The area should be clear of any rock or debris, and material should be kept under
protective cover to reduce exposure to dirt and limit damage. Light reflective StudLiner® should be
kept out of direct exposure to sunlight. Solmax can supply thin mil HD liners to act as a temporary
cover. Unloading of StudLiner® rolls should be performed by equipment that will lift the roll from the
center core. Rolls should be placed on a firm, smooth surface free of large, sharp stones.

B. Installation for Large Structures

The StudLiner® System installation involves a series of construction steps that have been coordnated
to increase the level of quality, reduce project costs by minimizing time involved, and to avoid damages
during the various installation phases. The following sequence has shown the best results for the
standard construction of a cast in place structure with StudLiner®:
1. Weld Wall panel joints in the ceiling area (when applicable)
2. Fix and weld ceiling panels (when applicable)
3. Weld wall panels
4. Install and weld floor panels
5. Concrete installation for the floor area

a. Wall Panel Fixation

1. If StudLiner® is received in roll form it is advised to lay out panels in order to facilitate
straightening of the material. Prior to attachment to formwork, unroll needed amount and
place weight on material to flatten. Replace temporary cover on StudLiner® roll.
Since the StudLiner® sheets will be custom sized for the formwork, the StudLiner® sheets must
remain covered to reduce thermal expansion from direct UV exposure after they have been
measured and cut. Controlling thermal expansion is critical for a quality installation. When
necessary, panels may be transported by crane or front-end loader into position to be fixed
onto the forms.

2. It is important all sheets are hung plumb so all joints can butt with the least amount of space
between sheets. Solmax offers pre-fabricated corner pieces made with StudLiner® if corner
pieces are preferred.

3. The panels are placed with the smooth side on the forms. StudLiner® sheets should be
secured to formwork by the use of mechanical attachments including nails, screws, tie wire or
banding. Screws or nails should be placed within 0.25 in of the edge of the sheet, placed every
12 in. Form ties will offer the support for the rest of the sheet. To prevent damage of the
StudLiner® sheet, the mechanical attachments must allow for some expansion of the StudLiner®
while awaiting the concrete pour. The formwork must be free of sharp objects that could
penetrate the StudLiner®. The StudLiner® panels are attached to the formwork prior to
installation of concrete reinforcement products (i.e., rebar). Note, do not mechanically attach
the interior structural steel (rebar) to the StudLiner® sheets. The rebar should be free-standing
to stay in place during the concrete pour. Damage to the StudLiner® sheets could occur if
interior structures come loose during the concrete pour. During mounting of the panels wave
formation in the liner must be minimized when the casts are in an upright position, however it
is easier to position and fix the panels onto the forms while they are still on the ground.
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 4. To eliminate gaps between panels, the seams can be overlapped approximately 4 in. This is
accomplished by removing the studs with a grinder or sharpened chisel or stud removal tool,
from the overlap portion of the bottom sheet (closest to the formwork) to ensure a smooth
overlap. In order to minimize penetrations in the StudLiner®, place attachments in overlap seam
where possible.

5. Prior to the concrete being poured, temporary sealing should be used to prevent concrete
from getting between the StudLiner® sheet seams. Such temporary sealing methods include
HDPE tape and/or hot air bonding to provide temporary attachment.

6. It is recommended that concrete pouring times occur during early morning, dusk, or
night hours when the StudLiner® sheet is thermally contracted. Care should be taken to ensure
StudLiner® embedment, a vibrator must be used to properly distribute the concrete. Allow for
curing of concrete prior to removal of formwork.

b. Wall Panel Joint Welding In the Ceiling Area

1. The joints in this area can be welded before the ceiling panels are installed. This will ensure
consistent ceiling to wall welding with one seam in the corner of the tank and will prevent
ceiling to wall overhead weld under the ceiling which is much more complex and time-consuming.

2. Wall panel welding can be brought forward if weather conditions allow, however, the possibility
of damage caused by form handling for the concrete ceiling work should be considered.

c. Ceiling Panel Fixation And Welding

When a ceiling is to be utilized within the structure, the following steps will help to ensure a
smooth installation.
1. The first step is to make sure that the reinforcement bars between the walls and ceiling are not
bent but in a vertical position. This will allow an adequate area in the corner that is required for
the extrusion welding equipment. Liner installation is also greatly simplified.

2. The panels are placed on the forms studs up. Adjacent panels are installed next to each other
and a grinder is used to fit them into corners. The panels are then tacked with a hot air gun.
A grinder is then also used to prepare the seam for welding. A copper wire is installed for
testing purposes whenever access with a vacuum box is difficult.

3. Standard seam welding is then performed. After welding of panel seams and panels to wall,
the extra length wall panel required to weld onto the ceiling is cut so as to accommodate
reinforced steel bars. It is advised that ceiling to wall panels be welded from the top side to
ease installation.

4. Please note, the lining work and surface appearance should be approved prior to installation of
the reinforced bars for the ceiling. This will expedite final approval of job.

d. Installation and Welding of Floor Panels Since the floor is the last area to be lined, a “relining”
technique is utilized by installing the StudLiner® with the assistance of grouting to the existing slab.
1. The existing concrete surface must fulfill specific conditions to ensure successful installation.
The most important criterion is proper cohesion between the concrete surface and grout
concrete. This can be determined through standard testing techniques when required. Normal
concrete screeding is usually sufficient for this requirement to be fulfilled.

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 2. It is possible to grout approx. 100 m2 (1,000 ft2) of floor surface a day with a standard crew. If
more than a day is required, the surface should be separated with a HDPE strip which is
installed into a slot in the floor and fixed with concrete. The StudLiner® is welded to this strip
to limit the grout or concrete flow. The installation of the strips should coincide with the seams
to minimize welding work.

3. The installation of the StudLiner® panels for the floor is similar to installation for the ceiling,
whereby the studs face the concrete. This side will be anchored into the grout. The panels are
overlapped, and the studs in this area have to be removed.

4. Both panels in the area of the seams are prepared and welded together. In the corner seams,
the horizontal seam covers the joints of the vertical ones. This reduces the possibility of weak
areas in comparison to the execution of seams on the walls covering the horizontal corner
seam (welding the wall panels after the installation and welding the floor).

e. Concrete Floor Installation

1. Concrete grout is filled into the area between the existing concrete floor and StudLiner® panels.
Option 1 – HDPE pipes are installed vertically to the panels by welding thus ensuring that the
concrete flows correctly and that the air exits properly. The distance between pipes shouldn’t
exceed 2.5 m (8 ft). Pipes in the corners of the tank will prevent trapped air from forming. Best
results are reached with 100 mm (4 in) diameter pipes having a length of 500 mm (20 in). The
StudLiner® panels should be ballasted with a load of not less than 400 kg/m2 (0.567 psi).
Various methods from water barrels to reverse forms can be used. For further information
contact Solmax.

2. The Concrete grout should be mixed and poured in one uninterrupted process. To prevent the
formation of trapped air, the concrete should be poured systematically in one direction. As
soon as the pipes are full and the concrete cannot flow into the room, the surface should be
knocked to locate trapped air. The ensuing vibrations will force the air into the next pipe. The
panel can be opened in certain areas to allow the air to escape.

3. After work completion, the pipes can be removed and a HDPE plate is used to cover holes.

4. Option 2 – Layout a grid on 8 foot centers or less, attach screed boards, HDPE, concrete, oak,
or plastic lumber. Attach to concrete matching the planned grid. Pre cut StudLiner® panels and
prefit to each grid. Fill the grid to be lined with grout and screed level. With the StudLiner®
prefit and rolled, place at one end and start to unroll, after the first 6 to 8 ft place a sheet
of plywood on top of the StudLiner®. You can tamp or use a jitterbug to vibrate on top of the
plywood to ensure entrapped air is removed. Place several sand bags on top of the plywood to
ensure a tight fit. Repeat until full panel is installed. Repeat until entire floor is completed.

C. Installation of Prefabricated Drop in Units Solmax can fabricate most any size and dimension of sump
or trench that is required to meet the various job criteria. These materials are supplied to the site ready
to be installed with minimal effort.

1. Place the prefabricated unit into predetermined location. This location should be prepared with an
exterior form to support concrete.

2. If an internal form was not supplied with the unit one will need to be constructed. The form should
be rigid enough to prevent collapse of the liner structure from weight of concrete.

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 3. Concrete is then poured using standard operations and procedures. Proper vibration and curing
techniques should be followed.

4. Once concrete is cured, forms are removed and any pipe or welding that is needed, is performed.

4.0 SEAM WELDING AND TESTING

A. Seaming
StudLiner® is manufactured from virgin high density polyethylene to produce a flexible, but strong
finished product with excellent stress crack resistance. These characteristics allow for the material to
be rewelded or patched, at any time during the life of the system provided that proper surface
preparation is performed. Field seaming involves bonding of adjacent panels using approved thermal
methods such as extrusion welding, wedge welding or electro-fusion welding. Testing and verification
of the resulting welds are imperative to a quality installations.

1. Installation Equipment
Standard HDPE Geomembrane welding equipment is used for welding of joints between
StudLiner® sheets and concrete formwork. This typically requires extrusion welder, wedge welder or
by use of the electro-fusion process.

2. Seaming Method
All field seams should be welded to provide a continuous impermeable barrier. This is typically done
by use of an extrusion welder. Extrusion welding incorporates hot, molten HDPE that is pressed
through a port onto the materials to be welded. The molten plastic then fuses with the exposed
surface(s) to create a homogenous bond of material.

3. Surface Preparation

a. As form work is stripped, all penetrations, tie rods, nail holes, and any damage in the
StudLiner® sheets must be identified and marked to speed the welding portion of the
installation.

b. Preparation of the material surface is vital to the quality of the weld. The surfaces must first be
cleaned, dried and free of debris prior to welding. In order to achieve a strong bond between
the extrusion material and the surface, the liner should be slightly scored using a grinder and
proper techniques. c. The welder should be set to parameters defined by the manufacturer of
the welding equipment. All seams and penetrations must be properly ground to roughen the
surface of the StudLiner® if an extrusion welder is to be used.

d. A copper wire can be inserted prior to welding so holiday spark testing can be performed on
extrusion weld seams. Whenever feasible, all welds shall be vacuum tested. Boot and weld all
pipe penetrations in accordance with Solmax drawings.

e. Wedge welding or electro-fusion welding require a dry clean surface for welding. A wipe-down
with a clean wet (water) rag may be used.

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 B. Trial Seams
Prior to any field welding of lined surface, it is advantageous to perform a trial seam to ensure that the
technician and method is adequate. Trial seams should be performed on materials from the current
project; three feet in length is adequate. Trial weld seams should then be tested to ensure equipment
settings are sufficient to produce quality welds. Testing can consist of both non-destructive and
destructive methods.

1. Non-Destructive Seam Testing

a. Non-destructive testing consists of primarily vacuum box testing.

b. Vacuum box testing per ASTM D5641-94 (01)e1 will be performed on all accessible welds
according to procedures set forth by manufacturer. Typically, a negative pressure of
approximately 5 psi shall be applied to the seam. A defect in the weld will be noted by the
presence of bubbles along the seam. The defect shall be marked and repaired with approved
methods.

c. Repairs of pinholes and defective areas should be performed by extruding a bead of molten
plastic over the surface, or if too large, a patch shall be utilized. Once complete, retest using the
vacuum box when.

d. If spark testing of the finished seams is required per ASTM D6365-99, a copper wire may be set
into the weld joint prior to welding. This will allow for spark testing for the welded seam for
determination of the presence of possible leaks in the weld. This process is not necessary but
may provide an alternative method for non-destructive testing of the welds. Spark testing
can be performed with approved instrumentation when set at approximately 20,000 to
35,000 volts depending upon thickness of material/extrusion weld. Any defects found should
be marked and repaired according to approved repair methods.

e. ASTM D4437 – 99 (known as the screwdriver test) may also be used in conjunction with spark
testing or vacuum testing.

2. Destructive Testing
Destructive testing is not advised once product has been embedded in concrete.

3. StudLiner® Final Sheet Test

After all seam welding and construction has been completed it is recommended that 100% of the
StudLiner® sheet be spark tested to ensure any construction damage has been repaired. Spark test
reference ASTM 6365 – 99.

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SOLMAX.COM

Solmax is not a design professional and has not performed any design services to determine if Solmax’s goods comply
with any project plans or specifications, or with the application or use of Solmax’s goods to any particular system,
project, purpose, installation or specification.