Geotechnical Construction and Testing to Home Improvements A61

General Construction Specifications

SECTION 02660

WATER DISTRIBUTION SYSTEM

PART 1 GENERAL

1.1 SUMMARY

Work under this section consist of providing all labor, material, equipment, tools and services required for the furnishing, installation, construction and testing of all water mains and appurtenances thereto required.

1.2 RELATED SECTIONS

A. Section 02222: Excavating

B. Section 02223: Backfilling

C. Section 03300: Concrete

1.3 UNIT PRICES

A. Water Mains Outside Roadway

Measurement for payment of water mains shall be made at the unit price per linear foot named in the Contract. The quantity to be paid shall be the actual number of lineal feet furnished and laid, by sizes and classes, as required. Measurement shall be made horizontally along the center line of the pipe in place, including valves, bends, reducers, off-sets and branches. Where water mains intersect and/or connect, measurement shall be made from the point of intersection of the centers of the two lines.

The unit price bid shall cover the cost of furnishing, installing, cutting, laying, jointing, incidental materials, making of all end connections, testing, sterilization, and all labor required to satisfactorily complete the work.

It is called to the Contractor's attention that the unit price bid shall also include the cost of all excavation blocking, crushed stone bedding and envelope, and backfill necessary for the complete installation of the water main and appurtenances; and no separate payment shall be allowed therefor.

The unit price bid shall not include crushed stone refill when ordered to be placed by the Engineer. It shall also not include iron fittings, valves and boxes, fire hydrants, tapping sleeves and valves and other units of work specifically set out in the Proposal and Contract, but will be paid separately under items listed.

Revised, May, 1995

B. Water Mains Inside Roadway

The unit price bid shall cover the cost of excavation, furnishing, installing, cutting, laying, jointing, incidental materials, making of all end connections, testing, sterilization, and all labor required to satisfactorily complete the work.

It is called to the Contractor's attention that the unit price bid include the cost of excavation, blocking, and crushed stone bedding and backfill necessary for the complete installation of the water main and appurtenances; and no separate payment shall be allowed therefor.

The unit price bid shall include crushed stone refill when ordered to be placed by the Engineer. It shall also not include iron fittings, valves and boxes, fire hydrants, tapping sleeves and valves and other units of work specifically set out in the Proposal and Contract, but will be paid separately under items listed.

C. Iron Fittings

Measurement for payment for furnishing and installing iron fittings shall be made at the unit price bid per pound named in the Contract. The quantity to be paid shall be based on the pounds furnished and installed complete, including tees, crosses, bends, reducers, plugs, caps, sleeves, off-set bends, and accessories. The basis for determining the weights will be the weights listed in the manufacture's catalog.

No separate payment will be made for blocking, or rodding.

D. Cutting and Capping Existing Water Mains

Payment for cutting and capping existing water mains will be made at the unit price bid per each as named in the Contract. The quantity to be paid for will be the actual number of mains cut and capped complete, including excavation and backfill. No separate payment will be made for excavation, backfill, rodding or blocking. Separate payment will be made for iron fittings and pipe installed as provided elsewhere in these specifications.

Revised, May, 1995

E. Water Service Lines

Measurement for payment of water service lines shall be made at the unit price bid per lineal foot for each size named in the Contract and as herein before specified. The quantity to be paid shall be the actual number of lineal feet for each size of water service line installed. Measurement shall be from the corporation stop of the new water main to the curb stop in at the proposed location of the meter box.

The price per lineal foot shall include excavation, (except rock excavation and gravel backfill) copper pipe, fittings, and all labor and materials necessary for installation of the water service line from the corporation stop on the new main to the curb stop at the proposed location of the meter box or to a point of connection with a satisfactory existing service line as herein before specified.

Separate payment shall be allowed for rock excavation, gravel backfill and the connection of service line to the new water main as detailed in item "New Tap and Connection to Water Main and/or Service Line."

F. New Tap and Connection to Water Main and/or Service Line

The unit price bid shall include any or all of the four (4) types of connections listed in Section 02660, paragraph 3.1-C, and all labor and materials which are necessary for a complete water main service line connection as specified herein before. The unit price shall also include disconnection and plugging the existing service from the old water main to be abandoned. Only one connection shall be paid for each set individual service line.

Separate payment shall be allowed for new service line installation in excess of two feet (2')as specified under item "Water Service Lines."

G. Water Meter Boxes

Measurement for payment of water meter boxes shall be made at the unit price per each named in the Contract. The quantity to be paid shall be the actual number of each size of new/or rebuilt water meter boxes installed. The unit price bid shall include excavation, brick sidewalls, frame and cover, backfill, and all labor and materials for a complete installation. Where an existing meter box is to be rebuilt, it shall also include the cost of removing the existing meter box.

Revised, May, 1995

H. Valves, Valve Boxes, Valve Vaults

Gate valves (12" and smaller), tapping sleeve and valves (12" and smaller), blow-off valve assemblies, and air-relief valve assemblies will be paid for at the unit price per each as named in the Contract. The quantity to be paid for will be the actual number of valves of each kind installed complete with valve box, frame, and cover and all appurtenances. Gate valves (16" and larger), tapping sleeves, and valves (16" and larger) will be paid for at the unit price per each named in the Contract.

The quantity to be paid for will be the actual number of valves of each kind installed complete with valve box, valve vault, frames and covers and all appurtenances. Butterfly valves (16" and larger) will be paid for at the unit price per each named in the Contract. The quantity to be paid for will be the actual number of valves installed complete with valve box, frames and covers and all appurtenances.

I. Fire Hydrants

Payment for furnishing and installing fire hydrant assemblies shall be made at the Contract unit price for each unit installed. The unit price shall cover all costs for materials, equipment and labor, fire hydrant, excavation, (except rock excavation and gravel backfill) backfill, concrete or stone blocking, rodding, testing and all other appurtenances necessary for the installation of the fire hydrant assembly, complete.

The unit price shall not include rock excavation, gravel backfill, ductile iron pipe, gray or ductile iron fittings, tapping valves and sleeves, valves and valve boxes, pavement replacement, top soiling and seeding, and other units of work specifically set out in the Proposal and Contract, but will be paid separately under items listed.

J. Miscellaneous Concrete

Miscellaneous concrete shall be paid for at the unit price bid named in the Contract based on the calculated quantities. This shall not include standard concrete blocking.

K. Crushed Stone Refill for Water Lines

Measurement of crushed stone refill made for the construction of water lines shall be computed from the formula: "trench depth" x "trench width" x "trench length" = allowable volume for payment expressed in cubic yards. Each dimension shall be as defined below:

1. "Trench depth" for refill shall equal the vertical centerline depth from a point 6 inches below the pipe installed to the bottom of the trench ordered by the Engineer below the aforesaid limit.

Revised, May, 1995

2. "Trench width" shall be as listed in the following table:

Pipe Size Trench Width

12" pipe & smaller 2.0 feet

16" & 18" pipe 2.5 feet

20" pipe 3.0 feet

24" pipe 3.5 feet

30" pipe 4.0 feet

36" pipe 4.5 feet

3. "Trench length" shall equal the actual horizontal measurement along the center line of the trench less the allowable horizontal dimensions of valve boxes and other appurtenances as specified below:

Where use of crushed stone refill is directed by the Engineer, it shall be paid per cubic yard of refill placed. Gravel refill placed at the discretion of the Contractor and not at the direction of the Engineer will not be paid for.

The crushed stone bedding, six (6) inches below the pipe and gravel backfilling to eight (8) above the pipe shall not be measured for payment under this unit of work, but shall be merged in the unit prices for other units of work of this Contract; and no separate payment shall be allowed therefore.

1.4 REFERENCE STANDARDS

A. American Waterworks Association (AWWA):

C500 Gate Valves 3" through 48" for Water and Sewerage System

C502 Dry-Barrel Fire Hydrants

C600 Installation of Ductile Iron Water Mains

C651 Disinfecting Water Mains

C800 Underground Service Line Valves and Fittings

B. American National Standards Institute (ANSI):

A-21.4 Cement Mortar Lining for Ductile Iron and Gray Iron Pipe and Fittings for Water.

A-21.10 Ductile Iron and Gray Iron Fittings, 3"-48" for Water and Other Liquids

A-21.11 Rubber Gasket Joints for Ductile Iron and Gray Iron Pressure Pipe Fittings

A-21.51 Ductile Iron Pipe, Centrifugally Cast in Metal Molds or Sand-Lined Molds, for Water or Other Liquids

C. American Society of Testing Materials (ASTM):

A-47 Malleable Iron Castings

A-48 Gray Iron Castings

B-88 Seamless Copper Water Tube

D-1784 Rigid Poly (Vinyl Chloride) Compounds and Chlorinated Poly (Vinyl Chloride) Compounds

D-2241 Poly Vinyl Chloride (PVC) Plastic Pipe (SDR-PR)

D-2666 Polybutylene (PB) Plastic Pipe

D-3139 Joints for Plastic Pressure Pipe Using Flexible Elastomeric Seals

E8-69 Tension Testing of Metallic Materials

D. Southern Standard Building Code

When materials and methods are indicated in these specifications as being in conformance with a standard specification, it shall refer in all cases to the latest edition of the specifications and shall include all interim revisions.

Listing of a standard specification without further reference indicates that the particular materials or method shall conform with such listed specification.

The attention of the Contractor is directed to Section 01090 where the full names of organizations publishing standard specifications are listed, and the abbreviations for said organizations are used herein, which said specifications are made a part hereof by reference.

1.5 SUBMITTALS

A. Shop Drawings

The Contractor shall submit, for the Engineer's approval, descriptive details and shop drawings covering full details of pipe, fittings, specials valves, tapping sleeves and valves, fire hydrants, joints and assembly thereof, joint materials and details thereof and full details and cuts of all castings to be incorporated within the work under this Contract.

B. Test Requirements

The attention of the Contractor is directed to Section 01410 of these specifications requiring the inspection and testing of materials to be incorporated in the work included under this Contract. The required tests shall be done by an independent testing laboratory, selected by the Contractor and approved by the Engineer. All such tests shall be at the expense of the Contractor, and no separate payment will be allowed therefor.

All materials to be incorporated in the construction of water mains and appurtenances required under this Contract shall be subject to inspections and tests as follows:

1. Ductile Iron Water Pipe and Fittings

The pipe manufacturer shall furnish the Engineer with certificates of inspection as required in this Section, paragraph 2.2-A.

2. Concrete

For each separate class of concrete of twenty-five (25) cubic yards placed, two (2) standard six-inch (6") concrete cylinders shall be made and tested.

The cylinders of each set shall be molded from the same sample of concrete and tested at seven (7) and twenty-eight (28) days.

Sampling of concrete for test purposes shall be per ASTM C-172. Testing of specimens shall be per ASTM C-39.

3. Miscellaneous Materials

All material used on this project shall be visually inspected by the Engineer at the site for conformance to the required specifications.

Where reasonable doubt exists that said material fails to meet the specifications, the Engineer may require certified mill test, samples and/or test by independent laboratory, or other suitable form of verification that the material meets the required specifications.

1.6 PRODUCT DELIVERY, STORAGE AND HANDLING

A. Materials delivered to site shall be inspected for damage, unloaded and stored with the minimum of handling. Store materials on site in enclosures or under protective coverings. Store materials above ground. Interior of pipe and fittings shall be kept free of dirt and debris.

B. Pipe, fittings, valves, hydrants and other accessories shall be handled to insure delivery to the point of installation in sound undamaged condition. If coatings or linings of pipe or fittings are damaged, such pipe or fittings shall be removed from the site and new materials furnished at no extra cost.

PART 2 PRODUCTS

2.1 General

All Material and equipment shall be furnished by an established and reputable manufacturer or supplier. All materials and equipment shall be new and shall be first-class ingredients and construction, designed and guaranteed to perform the service required and shall conform with the following specifications or shall be the product of the listed manufacturer or equal thereto as approved by the Engineer.

2.2 Materials

A. Pipe and Fittings

1. Ductile Iron Pipe Sizes 4" through 36"

The pipe furnished under this Contract shall be ductile cast iron pipe, centrifugally cast in sand lined or metal lined molds and shall conform to all requirements of ANSI A21.51 Standards and AWWA C-151.

The pipe shall be slip-type, single gasket joint, and plain end ductile cast iron pipe.

All pipe shall be made of good quality ductile iron and shall meet the requirements and standard specifications for Modular Iron Castings, ASTM Designation, E8-69 - Tension Testing of Metallic Materials (or latest revision).

The length of each piece of pipe shall be normal 18 feet and 20 feet laying lengths.

Pipe Class: All pipe shall have a wall thickness of Class 52, unless specified differently in the Special Provisions of this Contract Document and/or shown on the Contract Drawings.Pipe Class to be visibly cast or stamped on the outside of pipe.

Certificate of Inspection, List of Pipe Weights, etc: The pipe manufacturer is to furnish the Engineer a certificate of inspection, sworn to by the factory inspector in the presence of a Notary Public, stating that the pieces of pipe making up the shipment were made and tested in accordance with ANSI Specifications A21.51 and that they were subjected to and withstood a hydrostatic pressure of 500 pounds per square inch. Each statement is to give the number of pieces of pipe in the shipment, the length of each piece of pipe making up the shipment.

Cement Mortar Lining: All ductile iron pipe and fittings are to be cement lined at no extra cost, in accordance with ANSI A21.4 (AWWA C-104), or latest revision. Fittings can also be epoxy coated. Cement mortor or epoxy coated fittings should have NSF61 approval.

In addition a bituminous seal coat or Asphalt Emulsion Spray Coating shall be applied to the cement lining in accordance with the pipe manufacture's standard practice.

2. Ductile Iron Fittings or Gray Iron Fittings

All fittings under this Contract shall be mechanical joint ends and mechanical furnished joint and plan end fittings, ductile iron or gray iron, except as hereinafter specified and indicated on the Contract Drawings.

All gray iron fittings for sizes 4" through 12" shall be Class 250 and for sizes 14" through 48" shall be Class 150 in accordance with ANSI A21.10 (AWWA Specifications C-110). Fittings shall be furnished complete with glands, gaskets and bolts.

All ductile iron fittings for sizes 4" through 24" shall be Class 350 and for sizes 30" through 48" shall be Class 250 in accordance with ANSI/AWWA C-153-94 or ANSI A21.10 (AWWA Specifications C-110). Fittings shall be furnished complete with glands, gaskets and bolts.

Revised 9/27/00

Fittings shall be in accordance with standard mechanical joint fittings as manufactured by the U.S. Pipe and Foundry Company, American Cast Iron Pipe Company, James B. Clow and Sons, McWane Cast Iron Pipe Company, Griffin Pipe Products or an approved equal.

All fittings shall be cement mortar lined the same as specified for ductile cast iron pipe. Fittings can also be epoxy coated. Epoxy coated fittings should meet or exceed ANSI/AWWA C-550 & C-116/A21.16. Cement mortor or epoxy coated fittings should have NSF61 approval.

Each fitting shall have a notarized statement from the factory inspector furnished to the Engineer stating that said fittings were made in full compliance with the specifications.

3. Joints For Ductile Iron Pipe and Fittings

a. Joints for Ductile Iron Pipe

Slip-Type, Single Gasket Joints: The joints used with the pipe furnished under this Contract shall be the slip-type, single gasket joint and shall conform to all requirements of ANSI, A21.11 and AWWA C-111. The joints shall be good for a minimum of 200 pounds per square inch operating pressure.

The joints shall be "Fastite" as manufactured an American Cast Iron Pipe Company; "Tyton" as manufactured by U.S. Pipe & Foundry Company; "Bell-Tite" as manufactured by James B. Clow & Son; or an approved equal, all as approved by Underwriters Laboratories.

The bell shall have cast or machined gasket socket recesses, a tapered annular opening and flared socket design to provide maximum deflection. Plain spigot ends shall be suitably beveled to permit easy entry into bell, centering in the gasket and compression of gasket.

The gasket shall be suitably formed of high quality vulcanized rubber, made to exact dimensions, and in the form of a solid ring.

Sufficient lubricant shall be furnished with each order to provide a thin coat on each spigot end. The lubricant shall be non-toxic, shall impart no taste or odor to the water, and shall have no deleterious effect on the rubber gasket. The lubricant shall be of such consistency that it can be easily applied to the pipe in hot or cold weather and shall adhere to either wet or dry pipe.

Revised 9/27/00

b. Joints for Pipe Fittings

1) Mechanical Joints: The joints used with the mechanical joint fittings shall conform to all applicable provisions of slip-type, single gasket joints and as specified herein.

The joints shall be in accordance with standard mechanical joints as manufactured by the U.S. Pipe & Foundry Company, American Cast Iron Pipe Company, James B. Clow and Sons, McWane Cast Iron Pipe Company, Griffin Pipe Products, or any approved equal.

The joints shall be good for a minimum of 200 pounds per square inch operating pressure.

2) Slip-Type, Single Gasket Joints: Where slip-type, single gasket type fittings are approved by the Engineer for use, the joints shall conform to the requirements of the joints for ductile cast iron pipe, as specified herein.

B. Water Service Lines

Contractor shall furnish all service line pipe, valves and fittings conforming to:

1. Corporation Stops - Size as required for service - 3/4" minimum - Conforming to AWWA Standard C800 Tapered Pipe Threads - Mueller No. H-9971 (Copper Outlet), Hayes No. 5230 (Copper Outlet), Ford Meter Box Co. (F-200), or equal.

2. Quarter Bending Coupling (complete) - Mueller No. H-15490, Hayes No. 5314, Ford Meter Box Co. (L102-335 & 445), or equal.

3. Pipe - 3/4" minimum - Copper Type K, Soft Annealed - Conforming to ASTM B88-47.

4. Unions - Copper to Copper - Mueller No. H-15400, Hayes (S615), Ford (C22-33 & 34), or equal.

5. Couplings - Copper to Lead - Ford No. C-1100 Lead pack coupling.

6. Curb Stops - Mueller No. H-10201, Hayes No. 5000, or equal.

7. Y-Branch, 3/4" x 3/4" x 1" - Mueller No. H-15343, Hayes (5000), Ford (B11-233R or 344R), or equal.

C. Water Meter Boxes

All meter boxes shall be constructed of pre-cast concrete or brick in accordance with the details as shown on the Contract Drawings.

Brick used in constructing meter boxes shall be grade SW clay brick conforming to the requirements of ASTM C-62 and/or concrete brick Grade N-I, as per ASTM C-55.

Cement used in mortar shall be portland cement conforming to the requirements of ASTM C-150, Type 1.

Sand used in mortar shall conform to the requirements of ASTM C-33.

Water meter frames and covers shall be made of cast iron and conforming to the details shown on the Contract Drawings and meet the requirements of ASTM A-48, Class 30.

All castings shall be made accurately to the required dimensions and shall be sound, smooth, clean and free from blemishes or other defects. Defective castings which have been plugged or otherwise treated to remedy defects shall be rejected. Contact surfaces of frames and covers shall be hand ground so that the covers rest securely in the frames with no rocking. The cover shall be in contact with the frame for the entire perimeter of the contact surface.

D. Valves, Valve Boxes, Valve Vaults

1. Valves - Resilient Seated Gate (3" through 36")

These valves are conditionally approved for three (3) years, after which time the operating characteristics will be reviewed and a final approval list of manufactures adopted.

All valves to be furnished under these specifications must be either:

Clow Corporation (Oskaloosa, Iowa)

Clow AWWA, F-6100 Catalog 82

Mueller Company (Decatur, Illinois)

A-2370-20

American Darling (Birmingham, Alabama)

No. 85-CRS Gate Valve

Ken-Seal (Division of ITT-Grinnell) Elmira, New York

No. 1571-X

M & H (Bradford, PA)

Style 4067

U. S. Pipe (Birmingham, AL)

“Metroseal”

Stockham Valves & Fittings (Birmingham, AL)

Model G-701-0

Waterous (American Hoist & Derrick Co.) South St. Paul, Minnesota

Serves 500

Valves shall meet all applicable requirements of AWWA C509. Valves shall provide bubble tight closure up to 200 psi when closed and provide a clear, unobstructed waterway when open. Valves shall be non-rising stems with clockwise operation to open. The end configuration shall be mechanical joint. Stem seals shall be O-ring capable of replacement under pressure when valve is fully open. Resilient seats shall be bonded or mechanically attached to either the gate or valve body. If the resilient seat is rubber material, the method used for bonding or vulcanizing shall be proved by ASTM D429. The valves shall be hydrostatically tested with twice the specified rated pressure applied to one side of the gate and zero pressure on the other side. The test shall be made in each direction across the gate. Valves shall be epoxy-coated on the inside, including the interior of the gate, in accordance with AWWA C550. Outside of valve, including bolt holes, shall be coated with epoxy. The gate shall be provided with a drain in the bottom to flush the internal cavity of foreign material each time the valve is opened. All valves 16” & larger shall be horizontal in orientation.

The Contractor shall submit specifications and blueprints of manufacture showing detail dimensions and giving the kind of material used, also tensile strength and elastic limit of metal, and shall give weight of valves and diameter of stem at bottom of thread.

The Contractor shall furnish the Engineer with certificates of inspection, sworn to by the factory inspector in the presence of a Notary Pubic, stating that the valves were made and satisfactorily tested in full compliance with the specifications.

2. Valves- Horizontal Bevel Geared Gate Valves (16" through 30")

Note: Contractor to use these valves only when tapping large water main approved by the Engineer.

All valves shall be:

United States Pipe and Foundry Company (Birmingham, Alabama)

"Metropolitan",

Mueller Company (Decatur, Illinois)

Mueller AWWA (A-2380-20),

Dresser Manufacturing Division (Dresser Industries, Inc.) Anninston, Alabama

M & H AWWA NRS Style 67-01, or

American Valve & Hydrant Division (American Cast Iron Pipe Company) Birmingham, Alabama

American Darling No. 55.

The Contractor shall submit complete and detailed specifications covering the valve he proposed to furnish, including tensile strength and composition of valve stem and stem nut, and a detailed dimensioned print of the valve he proposed to furnish. The valves shall be mechanical joint end, horizontal, double gate, bevel geared valves, furnished with grease case and equipped with drain plug. Grease cases shall be simple and rugged in construction and shall be designed to provide reasonable access to the valve stem packing gland. By-pass for the valves (required on valves 20" in size and larger) shall satisfactorily meet the same pressure test as the main valves. By-pass valves shall open to the right (clockwise) and shall have a 2" square nut on top of stem.

Valves shall be of the parallel seat, double disc, bottom wedging type. The valves must embody the best workmanship and finish, open and close freely and easily. The wedging mechanism shall have multiple wedges of solid bronze and shall act on both gates equally and be entirely independent of the operating nut and spindle or the wedging mechanism shall consist of a cast iron bronze mounted bottom wedge cooperating with a bronze mounted top wedge. The top wedge shall contain a bronze stem nut. Wedge shall act to spread the gates evenly.

In opening, one gate shall move first, releasing the wedging mechanism before the second gate starts to rise. With the gates open, the valve shall afford an unobstructed waterway of diameter not less than the full nominal diameter of the valve.

Valves shall be designed to withstand a hydrostatic test pressure of 300 pounds per square inch, applied internally with the gates closed, and shall be guaranteed for not less than 150 pounds water working pressure. Valves shall open by turning the wrench nut to the right. Operating nuts shall be two inches square, and shall have cast on them an arrow indicating the direction of turning for opening the valve. All wearing and bearing faces of the valve shall be suitably proportioned, and all working parts shall be made of bronze or be bronze mounted.

Cast Iron: The body, bonnet, gates and others as specified shall be cast iron equal to or exceeding the requirements of ASTM A126, Class B. All castings shall be clean and sound, without defects of any kind. No plugging, welding or repairing of defects will be allowed.

Bronze: All bronze metal used in working parts of valves except stem and stem nut shall have a tensile strength of not less than 30,000 pounds per square inch.

Stem and stem nut shall be of Manganese Bronze or other non-corrodible metal, the stem having tensile strength of not less than 60,000 pounds per square inch and the stem nut a tensile strength of not less than 38,000 pounds per square inch and elongation of not less than 15% in two inches. Test bars shall be made and tested in accordance with the American Society for Testing Materials Specifications covering the materials used. Gate rings shall be cast bronze, rolled, peened, or pressed into grooves machined in the gates. They shall be further secured with bronze or suitable non-corrodible rivets, or rolled into dovetailed slots. Finish cuts shall be taken over the gate rings after they are finally secured in place. Body rings shall be cast bronze,carefully machined, the threads accurately cut, and the rings screwed into machined seats in the body.

Stuffing boxes shall have a depth not less than the diameter of valve stem to be passed. Glands shall be solid bronze ball-joint type with circular cast iron follower, or cast iron bronze brushed. The stuffing box and follower shall be secured properly with two or more bolts.

Gland bolts and nuts shall be bronze. All bolts and nuts except as otherwise specified, shall be hot-galvanized unless same cannot be secured at this time.

Cast Iron Gears: Except as otherwise explicitly required by supplementary specifications, geared valves shall be equipped with gears made of cast iron equal to or exceeding the requirements of ASTM A126, Class B, accurately formed and smooth running with steel pinion shaft operating in bronze or permanently sealed antifriction bearings. Gearing shall be designed for maximum facility and speed of operation with a minimum number of men.

Valves shall be furnished with Rensselaer integral type grease case, Ludlow conventional type grease case, or Iowa integral type grease case, and shall be furnished with drain plug. Grease cases shall be simple and rugged in construction and shall be designed to provide reasonable access to the valve stem packing gland. By-pass for the valve when required shall satisfactorily meet the same pressure test as the main valve. The valve must be suitable for safely opening or closing when subjected to full working water pressure on one side of gates and zero pressure on the other side, or such a condition as occurs when the pipe on either side of the valve breaks.

Valves shall be designed to lie horizontal in a horizontal pipe line and shall be equipped with solid bronze tracks securely fastened in body and bonnets, carrying the weight of the gates throughout their entire length of travel on rollers. The disc shall be carried on solid bronze rollers, securely attached to the gates; also, bronze scrappers shall be provided to traverse the tracks ahead of the rollers in both directions, removing any foreign matter which may have accumulated on the track. All iron work, after being thoroughly cleaned, shall be painted throughout with asphaltum varnish or dipped in suitable coating material. As minimum requirements, these valves must conform, in every respect, to the American Waterworks Association Specifications C500, for valves. All internal and external ferrous surfaces shall be fusion bonded (or approved equal) epoxy coated in accordance with AWWA C550.

An O-Ring stem seal will not be allowed for gear operated valves. The Contractor shall submit specifications and blueprints showing detail dimensions and giving the kind of metal used, also tensile strength and elastic limit of metal, and must give weight of valves and diameter of stem at bottom of thread. The Contractor shall furnish the Engineer with certificates of inspection, sworn to by the factory inspector, in the presence of a Notary Public, stating that the valves were made and satisfactorily tested in full compliance with the specifications.

3. Rubber Seated Butterfly Valves (16" through 48")

All valves to be furnished under these specifications must be manufactured by: Clow Corporation, Eddy-Iowa Division, Oskaloosa, Iowa; Dresser Manufacturing, Division of Dresser Industries, Inc., Anniston, Alabama, Henry Pratt Company, Aurora, Illinois; American Darling Valve manufactured by American Cast Iron Pipe Company, Birmingham, Alabama; Mueller Company, Lineseal, III, Decatur, Illinois; Allis-Chambers, Code 22 (16" - 24") and Streamseal (30" - 48"), P. O. Box M-93, York, Pennsylvania, or approved equal.

All butterfly valves shall be furnished for installation in a horizontal line with the operating nut in a vertical position. Each shall be furnished for buried service with a valve box as specified and as detailed on the Drawings.

All butterfly valves shall be of the tight closing, rubber seated type. Valves shall be bubble tight at rated pressures and shall be satisfactory for applications involving throttling service and/or frequent operations and for applications involving valve operation after long periods of inactivity. Valve discs shall rotate 90 degrees from the full open position to the tight shut position. Valves shall conform to Class 150-B of AWWA Specifications C-504, latest revision, except as otherwise noted. The manufacturer shall have manufactured tight closing rubber seated butterfly valves for a period of least five years. All valves shall be designed for the most severe operating conditions such as free discharge or "line break" conditions.

Valve bodies shall be constructed of cast iron ASTM A-126 Class B. Body thickness shall meet or exceed the requirements given in AWWA Specification C-504 or latest revision, Class 150-B Valves.

Valve discs shall be constructed of ductile iron conforming to ASTM A-536 or cast iron conforming to ASTM A48, Class 40 or alloy cast iron conforming to ASTM A-436, Type 1.

Shafts shall be constructed of either 18-8, Type 304 stainless steel, turned, ground and polished, mechanically secured to the valve disc by the use of 18.8, Type 304, stainless steel taper pins, or high-tensile carbon steel, furnished with permanent rubber static shaft seals and Type 304 stainless steel shaft journals to completely isolate the shaft from line fluid. Non-circular hex shafts will be acceptable.

Valve seats shall be of either new natural rubber or of synthetic rubber, Buna N compound. Rubber seats may be applied to either the body or the disc. Seats applied to the body shall be simultaneously molded and vulcanized into the body, and seat bond must withstand 75 lbs. pull under test procedure ASTM D-429, Method B. Rubber seats applied to the disc edge shall be vulcanized to an 18-8 stainless steel retainer ring which shall be clamped to the disc using 18-8 stainless steel locking screw fasteners. Valves with the rubber seat applied to the disc edge shall also have an 18-8 stainless steel seat integral with the body and machined to provide a permanent, corrosion resistant seating area. Valves employing a complete rubber liner will not be acceptable in any size.

Valves shall be fitted with sleeve type bearings. Bearings shall be corrosion resistant and self-lubricating.

Both valve ends shall be mechanical-joint as per AWWA Specification C-111. All internal and external ferrous surfaces, shall be epoxy coated (perferred fusion bonded or approved equal) in accordance to AWWA C 550.

Valve operators shall be designed to hold the valve in any intermediate position between full open or fully closed without creeping or fluttering. Valve operators shall be manual and shall be of the traveling nut type. Units shall be designed for buried service and shall be fully gasketed and grease packed. Adjustable mechanical stops shall be provided to stop valve in the fully opened and fully closed positions. The 2" square operating nut shall have cast on it an arrow indicating the direction of turning for opening the valve. Valves shall open with a clockwise rotation of the operating nut. Manual operators shall require at least 30 turns of the operating nut to rotate the disc 90 degrees.

Hydrostatic and leakage tests shall be conducted in compliance with AWWA Specifications C-504, and copies of the certified reports shall be submitted to the Engineer.

The Contractor shall submit specifications and blueprints of manufacturer showing detail dimensions and giving the kind of material used, also tensile strength and elastic limit of metal, and shall give weight of valves and diameter of stem at bottom of thread.

The Contractor shall furnish the Engineer with certificates of inspection, sworn to be the factory inspector in the presence of a Notary Public, stating that the valves were made and satisfactorily tested in full compliance with the specifications.

4. Tapping Sleeve and Valves(12" and smaller)

All tapping sleeves and valves shall be the product of either the U.S. Pipe and Foundry Company, Birmingham, Alabama; Mueller Company, Decatur, Illinois; M & H AWWA Class C, Division of Dresser Corporation, Anniston, Alabama; or Clow AWWA, as manufactured by the Clow Corporation, Eddy-Iowa Division, Oskaloosa, Iowa, American Darling Tapping Sleeve No. 1004 and Valve No. 565 only, and shall be suitable for use with an A.P. Smith tapping machine. The sleeve shall be held together by bolts, and the valves shall be bolted to sleeves. All sleeves must have a test tap. Rubber gaskets shall be furnished for use with the bolted sleeves. The valves on the connecting or outlet sides shall have mechanical joints suitable for cast iron or ductile iron pipe.

The valves shall be of standard make, double gate, cast iron body bronze mounted, to be vertical valves, open to the right (clockwise) have a 2" square nut on top of stems, and have oversize seat rings to permit entry of the tapping machine cutters. The valves shall be suitable for safely opening and closing when subjected to full working water pressure on one side of gates and zero pressure on the other side. Rubber gaskets shall be furnished for use between the flanges of the tapping sleeves and the tapping valve.

Revised February 25, 1998

All tapping sleeves and valves shall be tested at not less than 400 pounds per square inch hydrostatic pressure and be suitable and guaranteed to safely stand a working pressure of 200 pounds per square inch. As minimum requirements, these valves must conform in every respect to the AWWA specifications C500 for valves. The O-Ring stem will be accepted.

The Contractor shall submit specifications and blueprints of manufacture showing detail dimensions and giving the kind of metal used, also tensile strength and elastic limit of metal, and also shall give weight of valves and also the weight of sleeves and the diameter of stems at bottom of threads.

The Contractor shall furnish the Engineer with certificates of inspection, sworn to by the factory inspector, in the presence of a Notary Public, stating that the tapping sleeves and valves were made and satisfactorily tested in full compliance with the specifications.

5. Tapping Sleeves and Valves (16" and larger)

All tapping sleeves and valves must be the product of either U.S. Pipe and Foundry Company or American Valve & Hydrant Division (American Cast Iron Company), Birmingham, Alabama, American Darling, Mueller (through 18" only), M & H AWWA (through 18" only) or equal and must be suitable for use with an A.P. Smith tapping machine. The JCM 412 & Ford FTSC will be acceptable with prior approval of Metro Water for pit cast or old cast iron mains ONLY. The sleeves must be held together by bolts and valves are to be bolted to sleeves. All sleeves must have a test tap. Rubber gaskets must be furnished for use with the bolted sleeves and between the flanges of the tapping sleeve and the tapping valve. The valves on the connection or outlet sides are to have mechanical joints suitable for cast iron or ductile iron pipe.

The valves must be of standard make, double gate, cast iron body, bronze mounted with oversized seats to permit entry of the tapping machine cutters, have bevel gearing, set horizontal lie to the right or left when standing on sleeve and looking down on valve, as specified on order, open to the right (clockwise), have a 2" square not on top of stem.

Valves shall be furnished with grease case and equipped with drain plug. Grease cases shall be simple and rugged in construction and shall be designed to provide reasonable access to the valve stem packing gland. Bypass for the valve (required on valves 20" in size and larger) shall satisfactorily meet the same pressure test as the main valves. Bypass valves shall open to the right (clockwise) and shall have a 2" square nut on top of stem. Valves shall be designed to lie horizontal and shall be equipped with solid bronze tracks securely fastened in body and bonnets carrying the weight of the gates throughout their length of travel on rollers.

Revised February 25, 1998

The disc shall be carried on solid bronze rollers securely attached to the gates also bronze scrapers shall be provided to traverse the tracks ahead of the rollers in both directions, removing any foreign matter which may have accumulated on the tracks.

The valves must be suitable for safely opening or closing when subjected to full working water pressure on one side of gates and zero pressure on the other side or such a condition as occurs when the pipe on either side of the valve breaks.

All tapping sleeves and valves must be tested at not less than 300 pounds per square inch hydrostatic pressure and be suitable and guaranteed to safely stand a working water pressure of 150 pounds per square inch. As minimum requirements, these valves must conform in every respect to AWWA Standard C-500 for valves.

The Contractor shall submit specifications and blueprints of manufacturer showing detail dimensions and giving the kind of metal used, tensile strength and elastic limit of metal, weight of valves and also the weight of sleeves and the diameter of stems at bottom of threads. The Contractor shall furnish the Engineer with certificates of inspection, sworn to by the factory inspector, in the presence of a Notary Public, stating that the tapping sleeves and valves were made and satisfactorily tested in full compliance with the specifications.

6. Valve Boxes

All valve boxes with footing block shall be constructed in accordance with the details as shown on the Contract Drawings.

Valve boxes for valves up to and including 12 inches are to be made up of pre-cast concrete sections measuring 11" x 13 1/4" inside dimensions and 17" x 19 1/4" outside dimensions with a height of 12" to 15" for 8" through 12" valves and 15" to 18" for 6" valves and smaller. Reinforcement shall be placed as shown on the Contract Drawings and shall be deformed billet or rail steel bars conforming to the requirements of ASTM A615, Grade 60 or ASTM A616, Grade 60, respectively.

Footing blocks for standard concrete valve boxes are to be pre-cast in blocks measuring 12" x 12" x 4". No reinforcing steel is required.

The concrete mixture for valve boxes and footing block shall be one part cement, two parts sand, and four parts gravel or 1" crushed stone.

7. Valve Box and Valve Vault Frames and Covers

Valve box and valve vault frames and covers shall be made of cast iron and conforming to the details shown on the Contract Drawings and meeting the requirements of ASTM A-48, Class 30.

All casting shall be made accurately to the required dimensions and shall be sound, smooth, clear and free of blemishes or other defects. Defective castings which have been plugged or otherwise treated to remedy defects shall be rejected. Contact surfaces of frames and covers are to be hand ground that the covers rest securely in the frames with no rocking. The cover shall be in contact with the frame for the entire perimeter of the contact surface.

The manufacturer shall furnish the Engineer with certificates of inspection, sworn to by the factory inspector in the presence of a Notary Public, stating that frames and covers were made in full compliance with the specifications.

8. Water Valve Vaults

All water valve vault boxes 16 inches and larger shall be constructed of pre-cast sections or brick in accordance with the details as shown on the Contract Drawings.

Bricks shall be the same as those specified for water meter boxes.

Cement used in mortar shall be portland cement conforming to the requirements of ASTM C-150, Type 1.

Sand used in mortar shall conform to the requirements of ASTM C-33.

Water vault frames and covers shall be made of cast iron and conforming to the details shown on the Contract Drawings and meeting the requirements of ASTM A-48, Class 30.

Concrete for plain concrete base shall be Class "A" as specified in Section 03300.

All concrete shall be adequately protected from injurious action of the sun and in cold weather, or other method approved by the engineer.

9. One-Inch (1") Air Relief & Two-Inch (2") Blow-Off Valve Assemblies

Each one-inch (1") air relief and/or two-inch (2") blow-off valve assembly shall be constructed in accordance with the details as shown on the Contract Drawings.

Revised March, 1995

The corporation stop, curb stop, and copper pipe shall be as specified under paragraph 2.22 of this Section of these specifications.

E. Fire Hydrants

AWWA C502 "American Water Works Association Standard for Dry Barrel Fire Hydrants" shall apply except where the following supplementary specifications supersede.

Bury length shall be 3 1/2 feet unless otherwise indicated.

The hydrant outlets shall consist of one 4 1/2" outlet and two 2 1/2" outlets with nozzles and caps meeting NFPA No. 194-1974 "National Fire Protection Standard for Screw Threads and Gaskets for Hose Connections."

All fire hydrants shall be compression post type, opening against the pressure (AWWA C502).

Some approved method shall be provided to prevent the breaking of the expensive casting containing hydrant outlets in case of impact. Other expensive or hard to replace parts such as the stem shall likewise be protected.

The manufacturer shall furnish the drawings and data outlined in AWWA C502, and shall furnish 5 sets of certified drawings.

The Engineer shall be furnished with certificates of inspection, sworn to by the factory inspector in the presence of a Notary Public, stating that the hydrant and all material used in its construction conform to the applicable requirements of AWWA C502 and these supplementary specifications, that all tests specified therein have been performed and all tests requirements have been met. Records of such test shall be provided upon request.

The size of the hydrant's main valve shall be 4 1/2 inches.

The hydrant barrel is to be made in two sections with revolving upper section to provide for adjusting position of hydrant outlets. The upper flange connection must be at such a distance above ground line so as to easily remove bolts and revolve head part of hydrant.

All hydrants must be fitted with a mechanical joint inlet.

Lubrication must be possible without removing stem nut.

Hydrants shall have a 1" square operating nut on top of stem and on nozzle caps. The nozzle caps shall be chained or cabled to the barrel of the hydrant with a chain or cable constructed of material not less than 1/8" in diameter. The opening between the stem nut and the top of the bonnet shall be protected by a weather shield cap.

Revised March, 1995

There must be cast on top of the hydrant in characters raised 1/8" an arrow at 1 1/4 inches long and the word "open" in letters 1/2" high and 1/8" relief, indicating direction to turn to open the hydrant. Hydrants must open to the left (counterclockwise).

No stuffing boxes or glands shall be used.

O-rings or other approved seals of equal ease of operation shall be used.

Corners shall have good radius in accordance with good foundry practice.

Asphalt varnish and not primer shall be used for coatings.

Red paint shall be used for the final coat on the hydrant barrel top or head section.

The following fire hydrants are approved as meeting these specifications.

1. Mueller Centurion - supplied by the Mueller Company, 512 West Cerro Gordo Street, Decatur, Illinois 62525.

2. M. & H. Traffic Model - supplied by the M & H Valve & Fitting Company, a Division of Dresser, Box 2088, Anniston, Alabama 36202.

3. Matthews Modernized - supplied by the Kennedy Valve and Mfg. Co., Inc., Elmira, New York 14902.

4. American Darling - supplied by American Darling Valve, Box 2727, Birmingham, Alabama 35202.

5. Clow Corp. (F-2500) - supplied by Clow Corporation, 1211 West 22nd St., Oakbrook, Illinois 60521.

F. Miscellaneous Concrete and Concrete Blocking

Concrete for miscellaneous concrete and concrete blocking shall be Class "A" as specified in Section 03300.

PART 3 EXECUTION

3.1 INSTALLATION

A. Pipe and Fittings

1. General

Proper and suitable tools and appliances for the safe and convenient handling and laying of the pipes and fittings shall be used. Great care shall be taken to prevent the pipe coating from being damaged, particularly on the inside of the pipes and fittings. All pieces shall be carefully examined for defects, and no pieces shall be laid which are known to be defective. If any defective piece should be discovered after having been laid, it shall be removed and replaced with a sound one in a satisfactory manner by the Contractor at his own expense.

The pipe and fittings shall be thoroughly cleaned until they are accepted in the completed work and, when laid, shall conform accurately to the depth of cover below established grade designated herein.

Before lowering, each joint of pipe and/or fitting shall be brushed out and cleaned so that no loose or foreign material shall remain in the pipe. After the pipe is laid, the end shall be covered or plugged when not actually laying pipe, so that the pipe will be kept clean inside. The pipe shall be laid in a workmanlike manner and shall be laid to a straight and/or uniform line and grade without kinks or sags in the line.

2. Depth of Cover

All pipe and/or fittings shall be laid so that the top of the hubs shall have the minimum depth of cover below the finished grade of the road surface, shoulder, existing ground surface and/or drainage ditch, as the case may be. For each particular size of pipe the minimum cover is as follows:

Required Minimum Depth

Pipe Size in Inches of Cover in Inches

12" and Smaller 30"

16" and Larger 36"

The Engineer may, at his discretion where circumstances and conditions warrant, allow less than the required minimum depth of cover, but under no condition will there be permitted less than 24" of cover to the top of the hub from the finished grade of either the road surface, road shoulder, existing ground surface, and/or drainage ditch.

In traversing dips and rises and/or in order to avoid any underground obstructions such as sewers, conduits gas pipes, storm drains, etc., it becomes necessary for the Contractor to dig his ditch deeper than the required minimum depth shown; the Contractor must attain the necessary additional depth at no additional cost, and the cost of all such work shall be merged in the unit price bid.

3. Foundation and Bedding

All pipe and fittings shall be laid on good foundations, trimmed to shape and where required secured against settlement in a manner approved by the Engineer.

Pipes and fittings shall have a solid, even bearing throughout their entire length. Care shall be taken that the pipe is not supported on its bells. Bell holes shall be dug in the foundation under the pipe at each bell.

The foundation under, the bedding around and over, and the backfill within the trench for the pipe and fittings shall be specified in Section 02223 of these Specifications.

4. Joint Installation

Cleaning Joints: Immediately prior to the field assembly of the joint, the inside of the bell and the outside of the plain end of the pipe shall be carefully brushed with a wire brush and/or wiped with a clean rag, using soapy water, to remove any loose scale and rust and to provide absolutely clean surfaces for the hereinafter specified joints.

Immediately prior to the gasket being installed, it shall be wiped clean with a clean rag, using soapy water.

As the pipe is installed and the joint made up, care shall be taken to insure that these joint surfaces remain clean and free of any dirt or other foreign material.

Field Cuts: When the pipe is cut in the field, the rough, cut edge shall be smoothed with a file or portable grinder so that the plain cut end is beveled and will not damage the gasket in assembly of the joint.

Slip-Type Gasket Joint: In joining slip-type gasket pipe, the inside of the bell and the outside of the spigot end shall be thoroughly cleaned as specified. The circular rubber gasket shall be flexed inward and inserted in the gasket recess of the bell socket. A thin film of gasket lubricant shall be applied in accordance with the manufacturer's recommendation. Gasket lubricant shall be as supplied by the pipe manufacturer and approved by the Engineer. The spigot end of the pipe shall be entered into the socket with care used to keep the joint from contacting the ground. The joint shall then be completed by forcing the plain end to the bottom of the socket with a forked tool or jack-type tool or other device approved by the Engineer. Pipe that is not furnished with a depth mark shall be marked before assembly to assure that the spigot end is inserted to the full depth of the joint. Complete assembly shall be in strict conformance with the manufacturer's recommendations.

Mechanical Joints: Mechanical joint pipe shall be joined in accordance with the manufacturer's recommendations, and bolts shall be tightened with approved torque wrench or other approved means to secure uniform and allowable tension of the bolts. The pipe shall be installed to true alignment with the spigots carefully centered in the bells. Complete assembly shall be in strict conformance with the manufacturer's recommendations.

For water service, the norman range of bolt torques to be applied to standard cast iron bolts in a joint are:

Range of Torque

Size Inches Foot Pounds _

5/8 45 - 60

3/4 75 - 90

1 100 - 120

1 1/4 120 - 150

The above torque loads may be applied with torque measuring of indicating wrenches. Torque wrenches may be used to check the application of approximate torque loads applied by an average pull on a definite length of regular socket wrench.

The following lengths of wrenches should satisfactorily produce the above ranges of torques when used by the average man:

Length of Wrench

Size Inches Inches _

5/8 8

3/4 10

1 14

1 1/4 16

When tightening bolts, it is essential that the gland be brought up toward the pipe flange evenly, maintaining approximately the same distance between the gland and the face of the flange at all points around the socket. This may be done by partially tightening the bottom bolt first, then the top bolt, next the bolts at either side and last, the remaining bolts. Repeat this cycle until all bolts are within the above range of torques. If effective sealing is not attained at the maximum torque indicated above, the joint should be disassembled and reassembled after thorough cleaning. Overstressing of bolts to compensate for poor installation practice shall always be avoided.

5. Blocking

All bends 11 1/4 degree or greater, tees, crosses, plugs, pressure connections, etc., shall be backed up and anchored with concrete so that there will be no movement of the pipe in joints due to internal or external pressures. The cost of blocking shall be merged in the unit price bids.

6. Pressure Connection

Where connections are made to the existing distribution system, they shall be pressure connections. The Metropolitan Department of Water and Sewerage Services will furnish the tapping machine and the crew to make the tap. The Contractor shall furnish and install the tapping sleeve and valve, and shall perform all excavation, blocking, and backfill. The Contractor shall have the ditch open and be ready to actually make the connection prior to scheduled appointment of the tapping crew. The Contractor shall notify and give the Metropolitan Department of Water and Sewerage Services forty-eight (48) hours advance notice to schedule the tapping crew.

7. Shutting Down Water Mains

Where it is necessary to shut off water mains and/or pipes to make connections or for capping mains, the work shall be done as quickly as possible so as to cause the least inconvenience possible to the water consumers, but not exceeding four (4) hours.

All shut-downs shall be scheduled in writing by the Contractor and must be approved in advance by the Metropolitan Department of Water and Sewerage Services. If it is deemed necessary by said Department, critical shutdowns shall be scheduled for night and/or weekends.

The Contractor shall not operate any valves on existing water mains and/or water mains placed in service under this Contract without prior approval and only under the supervision of the Engineer.

The Contractor shall provide all water customers at least 24 hours notice of an intended shutdown, or interruption of water service.

8. Maintain Water Service

The water service to consumers, whose connections are to existing mains in the street where the proposed mains under the Contract are to be constructed, must be maintained by the Contractor so that they will not be deprived of water service while said proposed mains are being constructed.

9. Abandon Existing Water Mains

It shall be the responsibility of the Contractor to remove from the grounds all existing valve boxes over valves on abandoned mains.

All valves on the abandoned main shall be closed only when directed by the Engineer.

On valves to be abandoned, the frame and cover shall be removed and safely stored to prevent loss or damage until picked up by the Metropolitan Department of Water and Sewerage Services forces. The hole shall be filled with gravel and surface restored.

The cost of all work necessary to close valves as directed, remove frames and covers and fill the holes of the valves necessary to abandon existing water mains shall be merged in the unit prices bid; and no separate payment shall be allowed therefor. Where it is necessary to remove a valve frame and cover from a paved street, separate payment shall be allowed for temporary and/or permanent pavement restoration.

10. Construction Procedures

The installation of all mains under this Contract should generally proceed as follows:

a. The Contractor can, at his option, begin the installation of the water main at the connection to the existing system by two (2) means in conformance with the following:

1) The Contractor may begin construction without making any connection to the existing system. In this event, the new water line shall be temporarily capped near the proposed connection to the existing system. When the new water line is ready to be filled with water for testing and sampling, it shall be filled through a one-inch (1") copper jumper pipe tapped from the existing to the new water main. Upon completion of all required pressure and sterilization tests, the Contractor shall make the required connection to the existing water main and sleeve the new main into the new connection.

2) The Contractor may begin construction by making the required connection to the existing system. In this event, the existing system shall be separated from the new construction by two (2) consecutive valves. These two valves must remain closed at all times and only be operated under the close supervision of the Engineer to fill and/or flush the new pipe line.

This connection to the exist system may be made at one connection point only. Any other proposed connection points should remain free to allow the new pipe line to be flushed through a fire hydrant or other means. After the new pipe line is filled and flushed, water for the pressure test and samples should be obtained by placing a one-inch (1") copper jumper line around the new valves at the connection point. (This is done to keep the opening and closing of the connection point valves to an absolute minimum.) The new pipe line may be filled through the new valves and eliminate the copper jumper only with the prior approval of the Engineer due to hazardous connection point locations, etc.

This disinfection test must be conducted by the Contractor first. No pressure test will be allowed to be conducted on the new pipe line until the required samples have been taken and satisfactory results obtained. (This is prevent un-sampled water being forced through a bad valve at the connection point by the higher test pressures.)

The required pressure test should then be conducted by the Contractor. The Contractor shall be responsible that the valves shall pass the required pressure tests. If the valve should leak, it will be the Contractor's responsibility to cut and cap the line for testing purposes.

b. Install all new mains, fittings, valves and hydrants. Existing mains are to be in service at all times.

c. Test, sterilize and flush the new mains, then place them in service, continuing to maintain service in the existing mains.

d. Reconnect and/or tie-over existing service lines from existing mains to new mains. Install new service lines. Service lines are to be replaced as specified in paragraph 3.1-B of this Section.

e. After all services are removed from the existing water main, the existing main shall be abandoned by cutting and capping as required. All tie-in of the new water main shall then be completed.

f. Remove from the ground all existing valve boxes over valves on abandoned mains and restore the surface as specified herein.

g. Pursuit of Work: The Contractor shall plan and pursue the work, as herein specified, in such a manner as to maintain a work area confined to the immediate area of installation and shall be completed to the extent possible as the job progresses. This means that all valves, fire hydrants, air release valves, blow offs, valve boxes and other appurtenances, as may be necessary to complete the installation, shall be installed at the time the water main is installed. As soon as the installation is complete and prior to testing, the excavations shall be backfilled, as specified, and the excess material is to be removed. Any damage claims to private property shall be investigated promptly and followed by such corrective action as may be necessary. The work area shall also be cleaned immediately following the installation.

The purpose of the above requirements is to keep the inconvenience to the public at a minimum. It is also believed that such a procedure will result in reduced maintenance for the Contractor as well as reducing justifiable complaints from the affected property owners. It is realized that service lines must be installed at a later date, and the same procedure as outlined above shall be followed upon installation of the service line.

11. Cutting and Capping Exist Water Mains

At all locations shown on the plans or where directed by the Engineer, the Contractor shall cut and cap the existing water mains. This item shall include excavation, cutting existing water main, furnishing and installing an approved cap and necessary concrete blocking, backfill and all labor and materials required for a complete installation. The line shall be excavated to the supply main. Existing tapping sleeves and valves, complete with frames and covers, will be removed, and a new section of pipe of proper size will be sleeved in to restore supply. Where tees exist, they will be capped at the tee.

Any shutdown of existing mains that might be necessary shall be done as required under paragraph 3.1-A-7 of this Section.

B. Water Service Lines

This item shall include the replacement of existing substandard water services and the installation of new services where directed by the Engineer, or shown on the Contract drawings. It shall include excavation, backfilling, furnishing all material, providing temporary service lines (where necessary), and doing all labor and work necessary for the construction of the sizes and types of water service lines as listed in the Contract Documents.

All work on the reconnection or replacement of customer service lines shall be performed by a Licensed and Bonded Plumber. To this end the Contractor shall employ the services of a Licensed and Bonded Plumber (if the Contractor is not a Licensed and Bonded Plumber) to perform all service line work. This Licensed and Bonded Plumber shall be employed as a sub-contractor and must be approved by the Owner. This requirement shall not relieve the prime Contractor of responsibility for the entire installation and replacement of services to their original condition or as required as hereinbefore specified. The licensed and Bonded Plumber must obtain the necessary permits for each service line reconnection from the Engineering and Permits Section of the Department of Water and Sewerage Services for which no charge shall be made by the Department.

Existing service lines are to be replaced where they are smaller than 3/4" in size, or where they are galvanized iron lines, or where they are lead lines in poor condition. Existing copper service lines and lead service lines in good condition, that are 3/4" or larger, will not be replaced.

The water service line shall have a gooseneck, minimum length of twelve inches (12"), installed in each line. The gooseneck shall be adjacent to the water main and shall be supported with brick or concrete block supports (see standard Drawings). The service shall be laid in the trench, sufficiently weaving, to allow not less than one (1) foot extra length in its entire length. It shall be laid to a depth of at least two feet (2') below the grade of the street from the water main to the meter box.

The excavation, bedding and backfilling for service lines shall be the same as required for water mains.

Contractor shall furnish all service line pipe and fittings as shown in paragraph 2.2-B of this Section.

C. New Tap and Connection to Water Main and/or Service Line

This item shall include the following type of connections:

A. Connection of an existing service line in good condition to the new water main.

B. Connection of a new service line to the new water main.

C. Connection of a new service line to an existing service line in good condition.

D. Connection of a new service line to the curb stop in a new meter box, and/or connection to an existing meter in an existing meter box.

It shall include excavation, backfilling, furnishing all materials, including corporation stop, curb stop and up to two (2) lineal feet of the required diameter service line, and providing temporary service lines (where needed) and doing all labor and work necessary to make complete water main service line connections.

The excavation, bedding and backfilling for service lines shall be the same as required for water mains.

Each new water service or replacement of existing substandard service shall include a curb stop. The curb stop shall be at the end of the service and within the meter box.

Each new water service or replacement of existing substandard shall include a new tap and connection to the water main. Each water service pipe shall be connected to the water main through a brass corporation stop. The water main shall be tapped and the corporation stop inserted in the top of the water main under pressure. The Metropolitan Department of Water and Sewerage Services will furnish the tapping machine and the crew to make the tap. The Contractor shall furnish the brass corporation stop and shall perform all excavation, blocking and backfilling. The Contractor shall have the ditch open and be ready to actually make the connection prior to the scheduled appointment for the tapping crew.

D. Water Meter Boxes

Brick shall be lain in workmanship-like manner. Care shall be exercised to construct the walls plumb and square. Joints shall be broken in successive courses, and all joints shall be trowel struck, flush joints to provide a clean, smooth face on the inside and outside of the meter box.

Mortar for brick laying shall be proportioned by volume of one (1) part cement and two (2) parts sand.

Mortar shall be mixed in a suitable mixer or in a watertight mixing box. The materials shall be thoroughly mixed dry and then only sufficient water added to bring the mixture to a workable consistency. No mortar which has begun to set shall be used, and tempering thereof will not be permitted.

The water meter frame shall be set on the meter box sidewall in a full cement mortar bed at the required elevation. The frame and cover shall be set to conform to the exact slope, crown and/or grade of the surrounding area.

When existing substandard water service lines are being replaced, the existing meter shall be reinstalled as directed by the Metropolitan Department of Water and Sewerage Services.

On renewal of existing water meter boxes and/or where new services are installed, the end of the water service line shall be such that the top of the water meter is at least 22 inches and no more than 26 inches below finished grade.

E. Valves, Valve Boxes, Valve Vaults

This item shall include furnishing and installing valves, tapping sleeves and valves, valve boxes, and valve vaults, of the sizes and classes specified, at the locations shown on the Contract Drawings or as directed by the Engineer, all in compliance with these specifications. It shall also include all excavation and backfill, except as specified elsewhere in these specifications, furnishing and installing joint materials, and all other work necessary for a complete and usable installation.

Bricks shall be lain in a workmanship-like manner. Care shall be exercised to construct the walls plumb and square. Joints shall be broken in successive courses, and all joints shall be trowel struck, flush joints to provide a clean, smooth wall face on the inside and outside of the vault box.

Mortar for brick laying shall be proportioned by volume of one (1) part cement and two (2) parts sand.

F. Fire Hydrants

This item shall include furnishing and installing fire hydrants of the type specified at the locations as shown on the plans and/or in compliance with these specifications. It shall include all excavation and backfill, concrete for blocking, and rodding required for complete installation of fire hydrant.

It shall not include furnishing and installing valves, valve boxes, nor the tee on the water main, or other items of work set out in the Bidding Schedule of the Proposal and Agreement of this Contract.

AWWA C600 "American Water Works Association Standard for Installation of Cast-Iron Water Mains," sections entitles, "Hydrant Installation," and "Thrust Restraint," shall apply except where the following supplementary specifications supersede.

The material required for drainage around a fire hydrant shall be a minimum of 2 cubic feet of 2" broken stone. Crushed rock or sand shall not be used. The drain port shall not be plugged under any circumstances.

The fire hydrant shall be located not less than 12 inches nor more than 18 inches from the outside edge of curb to the front of the hydrant case.

Concrete block, a minimum of 12" x 12" x 4" thick, shall be required to wedge between hydrant base and back of trench and around the hydrant. Concrete blocks, 12" x 12" x 4" minimum, shall be used underneath hydrant. These slabs shall be wedged firmly behind and extending around the hydrant to undisturbed earth. The equivalent of poured concrete may be used, but the drain hole must not be clogged. Where such concrete restraints lack sufficient backing in the Engineer's opinion, the shoe or bowl of the hydrant shall be rodded to the valve.

The valve must be rodded to the tee.

Fire hydrant assemblies shall be visually inspected for leaks by the Engineer, under the existing main line pressure, for a ten minute (10) period. All visible leaks shall be repaired by the Contractor regardless of the amount of leakage.

G. Miscellaneous Concrete and Concrete Blocking

All concrete shall be adequately protected from injurious action of the sun by keeping it wet, covering with water-saturated covering, or other methods satisfactory to the Engineer.

Concrete shall be mixed and placed only when the temperature is a forty degrees (40o) F. or above and rising, unless specifically authorized by the Engineer, in which event all materials shall be heated in a manner approved by the Engineer. In freezing weather, suitable means shall be provided for maintaining the concrete at a temperature of at least fifty degrees (50o) F. for a period not less than seventy-two (72) hours after placing, or until the concrete has hardened. Salt, chemicals, or other foreign materials shall not be mixed with the concrete for the purpose of preventing freezing, unless approved by the Engineer.

All concrete shall be placed in the dry, upon clean, damp surfaces, free from water, and never upon soft mud or dry or frozen earth.

Freshly placed concrete shall be protected from wash by rain, flowing water, mud deposits and other injurious conditions.

Care shall be taken, when placing concrete, that the water pipe is not moved from its proper grade and alignment.

3.2 TESTING

A. General

All water mains and/or sections thereof constructed under this Contract shall meet or exceed the requirements of the Pressure and Leakage Test as specified hereinafter.

Where practical, pipe shall be tested in lengths between line valves or plugs of not more than one thousand (1,000) feet. Temporary test plugs and adequate blocking for tests shall be provided and installed by the Contractor.

The Contractor shall not make any connections to existing valves until the new pipe lines have been tested as required herein. Where special cases require that a connection be made to an existing valve, the connection shall be made only with the approval of the Engineer; and it shall be the responsibility of the Contractor that section of pipe meets the required tests.

In order to maintain satisfactory ingress and egress to public streets and private property and/or to avoid a hazard, the Contractor shall backfill the trench and be responsible that the water main meet all the required tests.

Depending on traffic conditions, public hazards, or other reasons, the Engineer may direct when tests of completed sections of water mains shall be made; and he may order such tests to be made on relatively short sections in order that hazardous areas may be backfilled promptly.

A meter and/or pressure gauge for measuring the required water and/or pressure as specified will be furnished by the Metropolitan Department of Water and Sewerage Services. All other necessary equipment, other than the meter for recording leakage, such as pumps, barrels, (copper pipe, fittings and temporary plugs, etc.) for testing, shall be furnished by the Contractor and maintained in a satisfactory work condition, all of which shall be considered an integral part of the Contract, and no additional payment will be allowed therefor.

The Contractor shall notify said Department forty-eight (48) hours previous to the day he plans to test a section of line so the Department can furnish its meter and/or recording pressure gauge on the stretch of line to be tested.

No allowance will be made for faulty seating of valves. The Contractor shall be held responsible to see that all valves are cleaned so as to seat properly. He will be required to remedy any condition in the section under test that might cause a greater leakage and/or loss of pressure that is set out herein and to continue to test the section until it meets the specified requirements.

B. Pressure Test

The Contractor shall conduct a pressure or strength test. Sections of the line may be tested from valve to valve by first filling the section to be tested with water from the Metropolitan Distribution system, then closing the valves to isolate the section. Each section or length of line is required to withstand, as a strength test, a minimum of 150 pounds per square inch pressure, or 1.5 times the operating pressure, for a period of four hours. This pressure shall be maintained by pumping from the Metropolitan main or a container, such as a barrel, into the section under test until the 150 pounds, or 1.5 times the operating pressure, has been attained and then maintaining the same for four hour intervals. Joints and line will be carefully examined for defects, excessive leakage or weakness. Water for this test will be furnished by the Metropolitan Government without charge to the Contractor.

C. Leakage Test

In addition to the pressure test, the Contractor shall conduct a leakage test. He shall maintain on the section under test for a period of not less than four hours a minimum hydrostatic pressure of 150 pounds per square inch, or 1.5 times the operating pressure. In no case shall there by any visible leakage, nor shall any leakage (as defined by AWWA C-600) in any stretch of pipe exceed 11.65 gallons per 24-hour per day per inch diameter per mile, as measured over a period of four hours in a manner approved by the Engineer. The above allowable leakage is for 18' length pipe. If other lengths of pipe are used, the allowable leakage shall be reduced in the ratio of 18 feet to the length of pipe actually used. Water for making tests will be furnished by the Metropolitan Government without cost to the Contractor.

Any defects, cracks, or leakage that may develop, or that may be discovered either in the joints or in the body of the pipe and fittings, shall be promptly made good by the Contractor, at his own expense, and to the satisfaction of the Engineer.

D. Disinfection

All pipe and fittings connected to or forming a part of a potable water supply shall be disinfected in a manner acceptable to the Engineer. The following method, or others acceptable to the State Department of Environment and Conservation and the Engineer, shall be used.

1. Flush out the new pipe lines until the water runs clear. This shall be done after the pressure tests and before disinfection. Each valved section of the newly laid pipe shall be flushed separately with potable water from the public supply.

2. Disinfect the pipe lines with chlorine applied either as a solution from chlorine cylinders through a potable solution feed chlorinator or by introduction of a hypochlorite solution. Calcium hypochlorite in commercial grades contain about 65% to 70% of free chlorine. Hypochlorite powder shall first be made into a paste and then thinned to about 1% chlorine solution. This will require about 7.50 gallons of water to each pound of powder.

Solution shall be prepared in a wooden barrel and the solids permitted to settle out. The clear supernatant shall be applied to the main through a rubber hose by gravity, siphonage, injection, or by suitable pump feeder.

3. The point of application of the chlorinating agent shall be at the beginning of the pipe line extensions, or any valved sections thereof, and through a corporation cock inserted in the top of the newly laid pipe. Water from the existing distribution system shall be controlled so as to flow slowly into the newly installed pipe line during the application of chlorine. The rate of chlorine mixture flow shall be in such proportion to the water entering the newly installed pipe that the chlorine dose applied to the new pipe shall not be less than 50 ppm and shall produce at least 25 ppm after 24 hours standing. Valves shall be manipulated so that the strong chlorine solution in the pipe being treated will not flow back into the line supplying the water.

4. Permit the treated water to remain in the pipe being treated for at least 24 hours, following which period the line shall be thoroughly flushed until all the heavily chlorinated water is removed. If, for any reason, a shorter retention period must be used, the chlorine concentration shall be increased accordingly.

5. Collect bacteriological water samples at maximum intervals of 1000 feet and from the end-most outlet of the treated pipe line. If the samples show safe results, the new pipe line may be placed in service. If, however, the results are unsafe, the chlorine treatment shall be repeated until samples show safe results.

Bacteriological tests will be run by the Plant Chemist of the Metropolitan Water and Sewerage Services Department. The Engineer will provide sample bottles, take the samples, and transport to the Plant Chemist. The Contractor will assist in this operation as required.

3.3 MAINTENANCE

Excavation, backfilling, cleanup and temporary pavement on any individual road or street in which water mains are installed shall be prosecuted concurrently with the water main installation to the point that satisfactory ingress and egress to public streets and private property can be maintained. The Contractor shall be responsible that the water main meet all tests for pressure and leakage as specified elsewhere in these specifications.

END OF SECTION

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