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    SECTION 02731

    FORCE MAINS

   PART 1 GENERAL

   1.01 SUMMARY

    A. Furnish and install raw sewage force mains and fittings of the sizes and materials specified at the locations and grades as shown on the drawings.

    B. Pipe and fittings for the raw sewage force mains shall be ductile iron or prestressed concrete cylinder pipe as specified hereinafter.

    C. Related Sections:

    1. Section 02222: Excavation

    2. Section 02223: Backfilling

   1.02 REFERENCES

    A. ANSI A21.4/AWWA C104 - Cement Mortar Lining for Ductile Iron and Gray Iron Pipe and Fittings for Water.

    B. ANSI A21.5/AWWA C105 - Polyethylene Encasement for Gray and Ductile Cast-Iron Piping for Water and Other Liquids.

    C. ANSI A21.10/AWWA C110 - Ductile Iron and Gray Iron Fittings, 3-Inch through 48-Inch, for Water and Other Liquids.

    D. ANSI A21.11/AWWA C111 - Rubber Gasket Joints for Ductile Iron and Gray Iron Pressure Pipe and Fittings.

    E. ANSI A21.51/AWWA C151 - Ductile Iron Pipe, Centrifugally Cast In Metal Molds or Sand Lined Molds for Water or Other Liquids.

    F. AWWA C301 - Prestressed Concrete Pressure Pipe, Steel Cylinder Type, for Water and Other Liquids.

    G. AWWA C600 - Installation of Cast Iron Water Mains.

    H. ASTM A36 - Structural Steel.

    I. ANSI A21.50/AWWA C150 - Thickness Design of Ductile Iron Pipe

    J. ASTM A569 - Steel, Carbon (0.15 Maximum Percent) Hot-Rolled Sheet and Strip Commercial Quality.

    K. ASTM A570 - Steel, Sheet and Strip, Carbon, Hot-Rolled, Structural Quality.

    L. ASTM A611 - Steel, Sheet, Carbon, Cold-Rolled, Structural Quality.

    M. ASTM A648 - Steel Wire, Hard Drawn for Prestressing Concrete Pipe.

    N. ASTM C39 - Compressive Strength of Cylindrical Concrete Specimens.

    O. ASTM C143 - Slump of Hydraulic Cement Concrete.

    P. ASTM C150 - Portland Cement.

    Q. ASTM C289 - Test Method for Potential Reactivity of Aggregates.

    R. ASTM C469 - Static Modulus of Elasticity and Poisson's Ratio of Concrete in Compression.

    S. ASTM D1248 - Polyethylene Plastic Molding and Extrusion Materials.

    T. ASTM G62 - Holiday Protection and Pipeline Coating

    U. ASI 214 - Recommended Practice for Evaluation of Strength Test Results of Concrete.

    V. ACI 305 - Hot Weather Concreting.

    W. AWS D1.1 - Structural Welding Code - Steel.

    X. AWWA Manual M9 - Concrete Pressure Pipe.

    Y. AWWA Manual M11 - Steel Pipe.

   1.03 SUBMITTALS

    A. Submit under provisions of Section 01300.

    B. Shop drawings: Submit shop drawings and project data for piping work showing pipe sizes, accessories, valves, gates, joint details; catalogue cuts of valves, gates and operators; hydrants; dimensions and sizes; supports, inserts, and hanger details; design calculations; details of reaction blocking and harnessing; and a complete piping layout with materials of construction referenced to applicable standard specifications. Shop drawings shall also show dimensions, configurations, and other pertinent data of equipment to which the piping connects to or relates to shall be provided. Failure to provide all information will result in the shop drawings being returned marked "Exceptions Noted - Resubmit".

    C. Certificates: Submit manufacturer's certificates of conformance.

    D. Test Reports: Submit certified copies of test reports.

   1.04 QUALITY ASSURANCE

    A. Pipe manufacturer shall supply pipe, fittings and related appurtenances and be responsible for their compatibility.

    B. Where materials and methods are specified to meet the requirements of a standard specification, it shall refer in all cases to the edition of the specification current at the time of bidding and shall include all revisions. Listing of a standard specification without further reference indicates that the particular material or method shall meet the requirements of the listed specification. See Section 01090 for the full name of organizations publishing standard specifications.

    C. All pipe installed under this project shall be certified by the manufacturer to be in conformance with the applicable standard specifications and a copy of the certification submitted to the Engineer.

   1.05 DELIVERY, STORAGE AND HANDLING

    A. Deliver to site, store, protect and handle pipe and fittings under the provisions of Section 01600.

    B. Protect pipe and fittings from physical damage including effects of weather, water, construction activities and construction debris.

    C. Force main pipe and fittings shall not be strung (stored) in advance of the pipe excavation in rights-of-way from sta. 72+25 to 105+00; 118+50 to 124+60; and 139+00 to 158+50. Only sufficient pipe for the daily laying period may be stored inside the work zone of a traffic control phase for these areas. In other areas pipe may be strung concurrent with traffic control phases. Manholes and appurtenances presenting a visual and/or traffic restriction also may not be stored in advance of daily use in the three indicated areas.

   PART 2 - PRODUCTS

   2.01 DUCTILE IRON PIPE

    A. Manufacturer

    1. American Cast Iron Pipe Company, Birmingham, AL.

    2. U.S. Pipe Company, Birmingham, AL

    3. Substitutions: Under provisions of Section 01600.

    B. Materials

    1. Ductile Iron Pipe: Slip-type, single gasket, compression joint conforming to ANSI, AWWA C111/A21.11 - latest revision.

    2. Design Pressure: 50 psi plus a surge allowance of 100 psi, with a safety factory of two (2) applied to the design internal pressure (design pressure 100 psi plus surge pressure (50 psi) = 200 psi). Minimum nominal thickness shall be Class 150. Sewage force main lines shall be tested after installation at 75 psi. Depth of cover as shown on plans and safety factor of two applied to external bearing load, and Type 4 laying conditions assumed for design (actual construction will require Type 5 laying conditions). Pipe shall be capable of carrying minimum pressure of 0 psi at external bearing loads.

    3. Coatings and Linings: (Urethane or Protecto).

    a. Interior lining: Urethane Lining.

    i. Manufacturer: Futura Coatings Inc., Hazelwood, MO.

    ii. Madison Chemical Ind., Forest Park, GA

    iii. Substitutions: Under provisions of Section 01600.

    b. Interior, Urethane Lining:

    i. Surface Preparation: Blast to SSPC-SP10 to a profile of 3.0 to 4.0 mils.

    ii. Primer Coat: EC 16410 applied at 2.0 to 3.0 mils DFT.

    iii. Finish Coat: Futura 529 Futura-Thane applied at 50.0 to 60.0 mils DFT. After lining, testing product for voids and holidays in accordance with ASTM G62, Method B, using a 7500 volt High Voltage Tester. The ends of the pipe (bells, spigot and shoulders) shall be coated with coal tar epoxy of sufficient thickness to pass the holiday test described in ASTM G62, Method A.

    c. Interior, Protecto Lining:

    i. Manufacturers: Vulcan Painters, Birmingham, Al or Permite Corporation, Atlanta, Ga.

    ii. Surface Preparation: Blast to SSPC-SP10 as it applies to ductile iron pipe.

    iii. Finish Coat: Apply Protecto 401 ceramic epoxy according to manufacturers recommendations. The minimum thickness shall be 40 mils.

    d. Exterior Buried:

    i. Asphaltic coating as per AWWA C151 and AWWA C110.

    ii. Encase in polyethylene wrap in accordance with ANSI A21.5/AWWA C105 locations as shown on the Drawings.

    e. Exterior Exposed:

    i. Manufacturer: Tnemec Co., Kansas City, Mo.

    ii. Substitutions: Under provisions of Section 01600.

    iii. Surface Preparation: Blast to SSPC-SP6 Commercial blast.

    iv. Primer Coat: Tnemec Series 66-1255 Hi-Build Epoxoline at 4.0-6.0 mils DFT.

    v. Finish Coat: Tnemec Series 74-Color Endura-Shield or equal 3.0-5.0 mils DFT. Provide full range of color selections, color to be selected by Engineer.

    4. Fittings: Fittings shall be ANSI/AWWA A21.10/C110 ductile iron suitable for an operating pressure of 150 psi, and shall be capable of withstanding hydrostatic test of three times the rated water working pressure, per ANSI/AWWA A21.10 C110.

    5. Restrained Joint Pipe:

    a. Restrained joints are required on every fitting and in areas designated on the Contract Drawings. The restrained joints shall be American Cast Iron Pipe Company's "Lok-Ring", U.S. Pipe "TR Flex" or equal. Minimum nominal thickness shall be Class 150.

    b. The manufacturer to furnish test results showing that restrained joints in the sizes specified have been successfully tested to at least 200 psi without leakage or failure.

    C. Source Quality Control

    1. Submit design calculations which show the joint is capable of withstanding a force of 800 kips for 64" and 700 kips for 60" being transferred longitudinally through the joint.

    2. The manufacturer to furnish test results showing that restrained joints in the sizes specified have been successfully tested to at least twice the specified pressure rating of the joint without leakage or failure.

    3. Ductile iron pipe to be tested for quality control per applicable sections of ANSI/AWWA A21.51/C151. The hydrostatic test to be modified to require each and every piece of pipe to be hydrostatically tested to a minimum of 500 psi. This hydrostatic test to be certified by the manufacturer to compliance with the Owner reserving the right to witness said tests.

    D. All sections of pipe shall have permanent pressure class identification markers on outside top of pipe. Markers shall be large enough and positioned to be visible from top of trench. Markers shall be located on each end of pipe.

   2.02 PRESTRESSED CONCRETE CYLINDER PIPE

    A. Manufacturer

    1. Price Brothers Company, Dayton, OH.

    2. Substitutions: Under provisions of Section 01600.

    B. Materials

    1. Joints: AWWA C301 - Grouted inside and outside after laying in accordance with the manufacturer's written instructions and as approved by the Engineer. Provide adequate curing time for grout prior to field application of epoxy at joints.

    2. a. Design Pressure: 50 psi plus a surge allowance of 100 psi with a safety factor of two (2) applied to the design internal pressure (design pressure (50 psi) plus surge pressure (100 psi) = 200 psi). Depth of cover as shown on plans and safety factor of two applied to external bearing load, Type 4 laying conditions assumed for design (actual construction will require Type 5 laying conditions). Pipe shall be capable of withstanding minimum pressure of 0 psi at described laying conditions.

    b. Design Classification:

    For purposes of identifying pipe on job site and identifying pipe in drawings, a depth of cover for pipe design is designated below:

    Depth of Cover Pipe Classification

    66" - 0-16.0 ft. Class A

    66" - 16.0-23.0 ft. Class B

    60" - 0-16.0 ft. Class A

    3. Coatings and Linings: (Urethane or Protecto).

    a. Interior lining: Urethane Lining.

    i. Manufacturer: Futura Coatings Inc., Hazelwood, MO.

    ii. Madison Chemical Ind., Forest Park, GA

    iii. Substitutions: Under provisions of Section 01600.

    b. Interior, Urethane Lining:

    i. Surface Preparation: Blast to SSPC-SP10 as it applies to prestressed concrete cylinder pipe.

    ii. Primer Coat: EC 16410 applied at 2.0 to 3.0 mils DFT.

    iii. Finish Coat: Futura 529 Futura-Thane applied at 50.0 to 60.0 mils DFT. After lining, testing product for voids and holidays in accordance with ASTM G62, Method B, using a 7500 volt High Voltage Tester. The ends of the pipe (bells, spigot and shoulders) shall be coated with coal tar epoxy of sufficient thickness to pass the holiday test described in ASTM G62, Method A.

    c. Interior, Protecto Lining:

    i. Manufacturers: Vulcan Painters, Birmingham, Al or Permite Corporation, Atlanta, Ga.

    ii. Surface Preparation: Blast to SSPC-SP10 as it applies to Prestressed concrete cylinder pipe.

    iii. Finish Coat: Apply Protecto 401 ceramic epoxy according to manufacturers recommendations. The minimum thickness shall be 40 mils. Joints shall be field coated per manufacturers recommendations

    d. Exterior Buried:

    i. Encase in polyethylene wrap in accordance with ANSI A21.51/AWWA C105 or apply asphaltic coating as per AWWA C151 and AWWA C110 at the locations as shown on the drawings.

    4. Fittings:

    a. Cut and welded steel plate type having a minimum thickness of 3/16-inch with mortar coating on the interior and exterior surfaces. Fittings employing supplemental external reinforcement cages not acceptable.

    b. Capable of withstanding the pressures and loads described herein. Meet applicable sections of AWWA C301.

    5. Restrained Joint Pipe:

    a. Restrained joints are required on every fitting and in areas designated on the Contract Drawings. The restrained joints shall be Price Brother Company "Snap-Ring" or "Harnessed Clamp" or equal joint shall be able to withstand a test pressure of 200 psi.

    b. The manufacturer to furnish test results showing that restrained joints in the sizes specified have been successfully tested to at least 200 psi without leakage or failure.

    6. All pipe shall be embedded cylinder pipe and designed per AWWA C301. The pipe will be so designed so that at the design internal pressure of 150 psi (50 psi design pressure plus 100 psi surge), the core will remain in compression. The elastic limit of the pipe shall be greater than the internal maximum pressure of 200 psi. All design calculations based on concrete strength set forth in Paragraphs 3.6.8 of AWWA C301; no thinner internal core will be allowed due to higher concrete strength and the resultant compression in the core shall not exceed 2400 psi. Any hairline cracks in the mortar coating shall be inspected by the pipe manufacturer and the Engineer prior to laying. Disposition of such pipe shall be as recommended by the pipe manufacturer and approved by the Engineer. Excessively cracked pipe will be rejected. The thickness of the mortar coating shall provide a minimum cover of 3/4-inch over the prestressing wire.

    7. Cement used for the core, slurry, mortar coating, and authorized repairs shall conform to the requirements of ASTM C150, Type II. No cement replacement materials or mineral admixtures shall be used without prior approval from the Owner's representative.

    8. Concrete and Mortar Mix Design: Manufacturer to submit concrete and mortar mix designs for review by the Owner's representative prior to fabrication of pipe, fittings and special pipe, etc. Proportions of materials for the mixtures shall be established on the basis of laboratory trail batches using the proposed materials and curing procedures. The following properties to be measured and reported in accordance with the respective method:

    Property Method

    Slump ASTM C143

    Compressive Strength ASTM C39

    Static Modulus of Elasticity ASTM C469

    9. Water-Cement Ratio: Calculated on the basis of aggregate in the saturated-surface dry condition. Proportions to be established to obtain the required average compressive strength by the methods of ACI 214 at a slump of 3-4 inches for embedded cylinder pipe, unless water reducing admixture is used, in which case the mix design will be based on a slump of 4-5 inches. Manufacturer shall obtain approval from Engineer prior to admixture usage.

    10. The prestressing wire for circumferential reinforcement shall conform to ASTM A648 Class II or III. Wire diameter shall not be less than 6 gauge. No wire shall be used which has been drawn to obtain the minimum strength for a class of wire higher than Class III. Interpolation of fractional classes between Classes II or III shall not be permitted. The pipe design shall be based on the minimum tensile strength of the wire class used and that value shall not exceed the minimum tensile strength specified in ASTM A648 for Class III. No wire lot having an ultimate strength exceeding the specified minimum for its class, in any single specimen, by more than 30,000 psi shall be used. The requirements of ASTM A648 shall be supplemented by the following modifications:

    a. Section 5.3 The wire shall be cold drawn to produce the desired mechanical properties. At no time during the wire drawing process shall the wire temperature of the finished wire temperature exceed 360 degrees F.

    b. Section 5.5 The rod and the wire shall be of American manufacturer.

    c. Section 7.1.1 Tensile requirements shall conform to Table 2 of ASTM A648 except as outlined in the following:

    Class III Tensile Strength

    Wire Gauge Min (ksi) Max. (ksi) _

    6 252 282

    1/4-inch 240 270

    5/16-inch 221 251

    d. Section 7.1.3 Location of Test Specimen. Test specimens shall be taken from the back of the coil and shall represent normal wire drawing conditions.

    e. Section 7.1.5 Reduction of area shall conform to 35 percent minimum. Fracture surfaces containing radical cracks extending to the surface or longitudinal splits visible to the unaided eye shall be cause for rejection.

    f. Section 7.3.1 One test specimen suitable for a 12-inch span shall be taken for each coil.

    g. Section 7.3.2 Test Method. The test specimen shall be cut into two pieces with a sharp bolt cutter. One of the resulting pieces shall then be cut within 4-inch of the original cut and the cut shall be made at 90 degrees to the original cut. Splitting visible to the unaided eye shall be cause for rejection.

    h. Section 7.4.1 One test specimen shall be taken for each three coils or fraction thereof in a lot.

    i. Section 7.4.1 Test Method. A test specimen 8-inch long between the testing machine grips shall be twisted on its axis for a total of three complete revolutions. The specimen shall then be removed from the testing machine and examined at a magnification of at least 5X. Longitudinal or spiral splits on the wire surface shall be cause for rejection. If it is required to bend the ends of the test specimen so that it can be fixed in the testing machine grips, splits occurring in the bent section shall not be cause for rejection.

    j. Section 9.1 The surface of the wire, as received, shall be smooth and free from across checking or torn surface. No serious die marks, scratches, pits, or seams may be present. The wire ends shall not split when cut. A light oxidation film shall not be cause for rejection; however, corroded or pitted wire shall not be used.

    k. Section 11.2 The wire manufacturer's certification that the wire was manufactured and tested in accordance with this specification, together with a report of all test results, shall be furnished at the time of shipment and shall be reviewed by the Owner's Representative prior to pipe manufacture.

    11. The prestress wire shall not be smaller than 6 gauge. Prestress wires shall be separated by a clear distance at least equal to the diameter of the prestress wire used, but not less than 1/16-inch at the end wraps and on bevels. Adjacent wires shall not touch at any point. End wraps shall not be placed more than 1-1/2-inch or less than 1-inch from the edge of the core to be coated with the full depth of the mortar coating. No pipe shall contain more than one splice without Owner's Representative approval. All wire breaks, and causes thereof, shall be reported to the Owner's Representative.

    12. The minimum design thickness of the core for embedded cylinder pipe shall be as shown in he following table:

    Diameter Core Thickness-Inches

    60-inch 4-1/2

    66-inch 5

    13. For embedded cylinder pipe, the thickness of the inner concrete lining shall not vary from the nominal dimension by more than 3/16-inch for 60-inch and 66-inch pipe.

    C. SOURCE QUALITY CONTROL

    1. Pipe to be produced by a manufacturer with at least five years experience as a manufacturer of the type of pipe specified herein, per AWWA C301, Section 1, furnished the following data:

    a. Design calculations (include pressure at which coating is in tension).

    b. Steel mill test reports.

    c. Rubber gasket test reports.

    d. Concrete aggregate test results including ASTM C289.

    e. Concrete cylinder test results from each shift's pour.

    f. Notarized certificate of compliance.

    2. Prestressed Concrete Cylinder Pipe: Each steel cylinder with joint rings welded to its ends shall be hydrostatically tested in accordance with AWWA C301, Paragraph 3.5.3. One completed pipe of each size and class to be furnished on this project, shall be raised slowly to the specified working pressure and held for 20 minutes. At the end of 20 minutes, the pipe shall be carefully examined for cracks in the mortar coating while the operating pressure is maintained inside the pipe. There shall be no cracks exceeding 12 inch in length anywhere on the pipe. Next the pressure shall be raised quickly to the specified operating pressure plus surge pressure, and examined immediately for cracks in the mortar coating. There shall be no cracks exceeding .003 inch wide over a continuous 12 inch of length anywhere on the pipe, nor a crack exceeding .002 inch wide over a continuous 12 inch of length in the barrel of the pipe. The barrel is defined as the coated portion of the pipe exclusive of 6 inch at the spigot end and 12 inch at the bell end. After this examination, the pressure shall be reduced to the specified operating pressure. After 5 minutes at the operating pressure, the mortar coating shall be carefully inspected for cracks. There shall be no cracks in the mortar coating exceeding 12 inch in length. Failure to meet any of the above criteria shall be cause for rejection of the design and any pipe already made to that design. It shall be permissible to keep the external mortar coating surfaces of the pipe wet for a period not exceeding 48 hours prior to the test. Prior to starting the test and throughout its duration, the coating shall be in a surface dry condition.

    3. One additional pipe for each size and strength class (minimum one test per 5,000 linear feet of pipe) shall be tested in the same manner described above for the original proof of design test. This pipe shall be selected at random by engineer or his representative. Should the pipe fail to pass the hydrostatic test, the engineer or his representative may randomly select 5 more pipe from the same lot, and each of these pipe will be subjected to the same hydrostatic test. If all 5 pipe pass, the lot will be acceptable, including the 5 pipe that passed the test. If any of the 5 additional pipe fail to pass the test, the entire lot will be rejected.

    D. All sections of pipe shall have permanent pressure class identification markers on outside top of pipe. Markers size shall be large enough and positioned to be visible from the top trench. Markers should be located on each end of pipe.

   2.04 COMPONENTS

    A. Ductile Iron Pipe

    1. Ductile iron pipe with welded on boss rated for 150 psi minimum liquid pressure on a Class 150 joint of pipe.

    2. Fittings: Fittings shall be ANSI/AWWA A21.10/C110 ductile iron suitable for an operating pressure of 150 psi, and shall be capable of withstanding hydrostatic test of three times the rated water working pressure, per ANSI/AWWA A21.10 C110.

    3. All bolts: stainless steel.

    B. Prestressed Concrete Cylinder Pipe

    1. Steel sheets and coils for pipe cylinders to conform to the current ASTM A570, Grade 30 or 33 or ASTM A569. If the manufacturer is unable to obtain steel sheets or coils to comply with the above through no fault of it's own, it may substitute, after receipt of approval from the Owner's Representative, cold-rolled steel conforming to the requirements of ASTM A611 with restrained joints shall be designed for a longitudinal stress not to exceed 45% of yield stress at Pw, nor 60% of yield stress at field test pressure. All steel shall be of American manufacturer.

    2. All connections to the pipe to be at fittings or cast-in connection pipes.

    3. All stainless steel bolts.

    C. Sewage Air and Vacuum Valves

    1. Sewage air and vacuum valves shall allow unrestricted venting or re-entry of air through it, during filling or draining of the force main, to prevent vacuum. The Sewage Air and Vacuum Valve shall incorporate two (2) stainless steel floats directly connected by a stainless steel float guide, to maintain an air gap between the bottom float and top shut-off float. The air gap shall retard waste solids from the fouling or clogging the top shut-off float. The internal baffle shall be fitted with a guide bushing and act to protect the shut-off float from direct air flow. The baffle shall retain the 45 degree Durometer Buna-N seat in place, without distortion, for tight shut-off. 

    2. All internals shall be easily removed through the top cover without removing the main valve from the lines. The complete valve shall withstand 500 psi test. Inlet and blow off valves, quick disconnect couplings and minimum 5' hose for flushing shall be furnished with each valve.

    3. The valve inlet shall be as indicated on the drawings. Materials of construction shall be certified the following A.S.T.M. specifications:

    Body, Cover & Baffle Cast Iron ASTM A126 GR.B

    Cover & Upper Float Stainless Steel ASTM A240

    Stem, Guide Bushing

    Seat Buna-N Nitrile Rubber

    Exterior Paint Phenolic Primer FDA Approved for

    Red Oxide Potable Water

    Lining 8 to 12 Mil Epoxy

    Valves shall be Apco Series 408WA or equal.

    D. Sewage Air Release Valves

    1. Sewage Air Release Valves shall have an elongated body and be designed to operate (open) while pressurized, allowing entrained air in a sewage force main line, or sewage pump, to escape through the air release orifice without spillage or spurt. After entrained air escapes through the air release orifice, the valve orifice shall be closed by a needle mounted on compound lever mechanism, and prevent media from escaping. The air release orifice will then remain closed until more air accumulates and the opening cycle repeats automatically. The internal compound lever mechanism shall be stainless steel to prevent corrosion. Inlet and blow off valves, quick disconnect couplings and minimum 5' hose for flushing shall be furnished with each valve.

    2. The internal linkage shall be fitted with a stem, having a stainless steel float threaded onto the opposite end. The float shall hang inside the valve body, slightly above the inlet 13" from the lever mechanism, thereby maintaining an air gap between the mechanism and the waste media. The valve body and float shall withstand 500 psi shell test pressure. The valve inlet shall be as indicated on the drawings. Materials of construction shall be certified the following A.S.T.M. specifications:

    Body, Cover & Baffle Cast Iron ASTM A126 GR.B

    Internal Linkage System

    Float Stainless Steel ASTM A240

    Needle Buna-N Nitrile Rubber

    Exterior Paint Phenolic Primer FDA Approved for

    Red Oxide Potable Water

    Lining 8 to 12 Mil Epoxy

    Valves shall be Apco Series 450WA or equal.

   2.05 FABRICATION

    A. Ductile Iron Pipe: Fabrication as per ANSI A21.10/AWWA C110.

    B. Prestressed Concrete Cylinder Pipe.

    1. Mixing

    a. The temperature of the mix shall not exceed 90 degrees F. at the time of placement without positive steps being taken to reduce the temperature and/or control it's effect on the quality of the concrete. Such steps shall include, but not be limited to, the recommendations contained in "Hot Weather Concreting" as reported by ACI Committee 305.

    b. The measured slump of the concrete used in embedded-cylinder pipe not to vary more than 1 inch from the approved mix design, as measured at the mixer discharge. Pipe made with a concrete slump exceeding this limit subject to rejection.

    2. Curing of Core

    a. Cores cured by the accelerated curing method only. The total continuous cure including the delay period but excluding the time required to remove the forms or end rings to a minimum of 12 hours.

    b. Do not remove forms or rings until after a minimum of 6 hours of accelerated curing, including the required 4-hour delay period.

    3. Placing of Wire Reinforcement

    a. The temperature of the cores to be at least 40 degrees F. and the cores to be in surface dry condition at the time of prestressing.

    b. Any required patches to be adequately cured prior to prestress and finished in such a manner as to prevent bridging or gaps under the prestress wire.

    c. Tension in the wire during the prestressing operation to be continuously recorded. The mean tension to be that specified to produce the required stress in the wire. Normal fluctuations in tension not to deviate from the mean by more than 10 percent. No more than 5 percent of the wraps to have instantaneous fluctuations exceeding the 10 percent deviation.

    d. As the wire reinforcement is being placed, apply a slurry per AWWA C301.

    4. Pipe Mortar Coating

    a. The mortar coating to be applied within 16 hours after prestressing. Protect uncoated prestressed pipe as necessary so there is no free water or contamination of the surface.

    b. Temperature of the pipe: at least 40 degrees F. at the time of coating.

    5. Curing of Mortar Coating

    a. All cement mortar coating to be cured by the accelerated method only and shall be continuous for a minimum of 12 hours, including the four hour delay period.

    6. Fittings

    a. Steel plate or sheet. Before rolling or forming longitudinal edges, lap break all plates by a continuous rolling operation or form in a press having dies that are machined to proper radius. The pressure exerted during the lap breaking operation shall be sufficient to secure a uniform curve at the edges of the plate.

    b. Remove all scale and other foreign matter accumulating on the plate during rolling and forming operation by an air blast so that it will not be rolled or pressed into the surface of the plate. Complete all rolling and forming prior to making butt welds.

    c. Do not heat or hammer for the necessary forming of angles.

    d. Cleaning: Prior to welding, clean the surfaces of all plates and members to be welded of all scale and rust for a distance of not less than 1 inch and of all oil or grease for a distance of not less than 3 inch from the welding edge on both sides of the plates in the case of butt joints.

    e. Aligning: Where butt-welded joints are used, align edges to be jointed to ensure complete penetration and fusion at the bottom of the joint. Limit the offset in abutting edges to 1/16 inch at circumferential seams and to 1/32 inch at longitudinal seams.

    f. Qualification: All welding operations to be qualified under the qualification procedure of the ASME Boiler and Pressure Vessel Code, Section IX, Welding Qualifications, or the AWS D1.1. Any welder or welding operator performing work to have been qualified for the process within the past three years.

    g. Quality of Welds: Butt welds not to be made prior to the completion of the rolling and forming. All butt welds for both hand and automatic welding ground out to sound metal before welding reverse side.

    h. Longitudinal seams welded before girth seams. All welds to be full strength, ductile, and made with a technique which will ensure uniform distribution of load throughout the welded section.

    i. All welded joints to be of a type that will produce complete fusion of the plates and shall be free from unsound metal, pinholes, and cracks.

    j. The finish of welded joints to be uniform, smooth, and free from grooves, depressions, burrs and other irregularities. No valley or undercut in the center or edges of any weld acceptable.

    k. Flanges to be flat faced. The gasket surfaces to have a V-serrated finish of approximately 32 serrations per inch, approximately 1/64 inch deep.

    l. Welding-type outlets to have a mounting diameter the same as that of the surface upon which they are to be mounted, except that where the mounting surface is curved to a diameter of 36 inch or more, the outlet bottom may be flat. Welding-type outlets to be forged steel.

    m. Steel plate fittings designed in accordance with AWWA M11. Steel plate shall conform to ASTM A36 or equal.

    n. Mortar Lining and Coating. The inside diameter of the pipe and other fabricated fittings to be as specified after the application of the interior mortar lining.

    7. Outlets and Connections

    a. Openings for manholes and connections for air valves, blow-offs, and other branches shall be built into the walls of the concrete pipe and designed in accordance with AWWA M11.

    b. In all cases, the primary steel reinforcement not to be in the form of a collar. In the case where a collar is sufficient reinforcement according to AWWA M11, a 360 degree wrapper will be substituted. If secondary reinforcement is required by the AWWA M11 procedure, a collar may be used.

    c. The steel plate to conform to ASTM A36 or an equal.

    d. The wrapper thickness no greater than four times the thickness of the cylinder in the concrete pipe section.

    e. The wrapper shall be welded to the exterior of the cylinder between the circumferential welds removed. The welds shall be hydrostatically tested for their entire circumference.

   PART 3 EXECUTION

   3.01 INSTALLATION

    A. Laying and installation of force mains shall be as detailed on the Drawings.

    B. Submit to the Engineer within four calendar weeks after the Notice to Proceed, a laying schedule for pipe and fittings. The schedule to be based on the actual field stake out and reviewed by the Engineer prior to construction.

    C. Concrete Pressure Pipe to be stored, handled and transported in a manner that protects the pipe from damage due to heat, drying or injurious stress. Pipe handling and transportation considerations as per AWWA Manual M9.

    D. Install the pipe and fittings in accordance with the project plans and specifications and the manufacturer's recommendations.

   3.02 APPLICATION

    A. Pipe Joint Deflection and Fittings Required:

    1. Fittings shown on the Drawings are intended to convey the general configuration of the force main but the Contractor shall furnish all fittings and/or pipe bevels required to install the force main as shown.

    2. Limit the deflection at the pipe joint to that recommended by the manufacturer of the pipe furnished. The Contractor to carefully examine the Drawings to determine if fittings or bevels in addition to those shown shall be required for laying the force main due to limited allowable deflection of the pipe joint. The cost of any fittings required due to limited deflection will not be a separate pay item but shall be included in the other bid prices.

   3.03 FIELD QUALITY CONTROL

    A. TESTS

    1. Perform preliminary inspection/test.

    a. To demonstrate that the pipe and the pipe coating specials and fittings have not been damaged during shipping, storage and installation.

    b. After the pipe trench has been prepared as per specifications and as shown on drawings.

    c. After proper pipe bedding as shown on drawings has been provided before the pipe is installed.

    d. After all field joint assembly has been done in accordance with the specifications.

    e. After anchors and/or thrust blocks have been provided.

    f. After backfilling has been done as specified and as shown on drawings.

    g. After specials, fittings and appurtenances have been properly connected.

    2. Ductile Iron Pipe

    a. Prefinal inspection/testing consists of conducting the hydrostatic field test as described in Section 4.1 of AWWA C600.

    b. The test pressure to be 75 psi maintained for a minimum of four (4) hours. Conduct a leakage test concurrently with the hydrostatic pressure test in accordance with AWWA C600, Section 4.1. The allowable leakage not to exceed 6.41 gallons per hour per 1,000 linear feet of pipeline tested.

    c. Repair or replace any section of pipeline including specials, fittings and appurtenances discovered to be damaged after the hydrostatic test with sound material and repeat the test to the satisfaction of the Owner's Representative.

    3. Prestressed Concrete Cylinder Pipe

    a. Upon completion of the pipeline bulkhead and fill the pipe with water and allow to soak under low pressure to allow the pipe walls to absorb water and for temperature stabilization.

    b. Properly bleed off trapped air while filling the line.

    c. Pressure test to 75 psi for a minimum of four hours.

    d. Conduct a leakage test concurrent with the hydrostatic pressure test. Allowable leakage not to exceed 6.41 gallons per hour per 1000 linear feet of pipeline tested.

    e. Repair or replace any section of pipeline including specials, fittings, and appurtenances discovered to be damaged after the hydrostatic test with sound material and repeat the test to the satisfaction of the Owner's Representative.

    f. If any test of pipe installed indicates leakage of 6.41 gallons per hour per 1,000 linear feet of pipeline tested, the Contractor shall at his own expense, locate and repair the source of leak in the pipeline until the leakage is within the specified allowance.

    g. All visible leaks are to be repaired regardless of the amount of leakage.

    4. Perform Inspection/Test

    a. The inspection/test shall demonstrate that under conditions of testing and operation, the pipeline:

    1. Is free of any pipe and pipe coating damages.

    2. Is free of any visible leaks.

    3. The allowable leakage is less than that specified.

    4. Will operate at the design internal pressure without any damage to the system.

    b. Testing shall be accomplished in four phases with each test being cumulative to the previous test. The tests shall be staged as follows:

    Approximate

    Tests Stations

    1 0+00 to 22+60

    2 29+40 to 89+43

    3 29+40 to 126+50

    4 29+40 to 169+35

    If the river crossing (station 22+60 to 29+40) by others is installed and successfully tested prior to testing the force main, all tests will begin at station 0+00, if the contractor was ordered to connect the force main.

    END OF SECTION