02730 _ Sewer _ Accessories.pdf

SEWERS AND ACCESSORIES

02730-1

LOWNDES COUNTY, GEORGIA LEA Project #0010-172

DISCHARGE MANHOLE REPLACEMENT NOV 2024

PART 1 GENERAL

1.01 SCOPE

A. This Section describes products to be incorporated into sewers and accessories and requirements for the installation and use of these items. Furnish all products and perform all labor necessary to fulfill the requirements of these Specifications.

B. General: Supply all products and perform all work in accordance with applicable

American Society for Testing and Material (ASTM), American Water Works Association (AWWA), American National Standards Institute (ANSI), or other recognized standards. Latest revisions of all standards are applicable.

1.02 QUALIFICATIONS

If requested by the County, submit evidence that manufacturers have consistently produced products of satisfactory quality and performance for a period of at least two years.

1.03 SUBMITTALS

Complete shop drawings, product data and engineering data, including shop drawings, shall be submitted to the County.

1.04 TRANSPORTATION AND HANDLING

A. Unloading: Furnish equipment and facilities for unloading, handling, distributing and storing pipe, fittings, valves and accessories. Make equipment available at all times for use in unloading. Do not drop or dump materials. Any materials dropped or dumped will be subject to rejection without additional justification.

B. Handling: Handle pipe, fittings, valves and accessories carefully to prevent shock or damage. Handle pipe by rolling on skids, forklift, or front loader. Do not use material damaged in handling.

C. Lined pipe shall be handled and transported to prevent damage to linings.

1.05 STORAGE AND PROTECTION

A. Store all pipe which cannot be distributed along the route. Make arrangements for the use of suitable storage areas.

02730-2

LEA Project #0010-172 LOWNDES COUNTY, GEORGIA

NOV 2024 DISCHARGE MANHOLE REPLACEMENT

B. Stored materials shall be kept safe from damage. The interior of all pipe, fittings and other appurtenances shall be kept free from dirt or foreign matter at all times.

C. Pipe shall not be stacked higher than the limits recommended by the manufacturer.

The bottom tier shall be kept off the ground on timbers, rails or concrete. Pipe in tiers shall be alternated: bell, plain end; bell, plain end. At least two rows of timbers shall be placed between tiers and chocks, affixed to each other in order to prevent movement. The timbers shall be large enough to prevent contact between the pipe in adjacent tiers.

D. Store joint gaskets in a cool location, out of direct sunlight. Gaskets shall not come in contact with petroleum products. Gaskets shall be used on a first-in, first-out basis.

1.06 QUALITY ASSURANCE

A. Product manufacturers shall provide the County with written certification that all products furnished comply with all applicable provisions of these Specifications.

B. If ordered by the County, each pipe manufacturer shall furnish the services of a competent factory representative to supervise and/or inspect the installation of pipe.

This service will be furnished for a minimum of five days during initial pipe installation.

1.07 RELATED SECTIONS

1. Section 02200-Basic Pipeline Construction

PART 2 PRODUCTS

2.01 DUCTILE IRON PIPE (DIP)

A. Ductile iron pipe shall be utilized where shown on the Drawings. All pipe, except specials, shall be furnished in nominal lengths of 18 to 20 feet, with a bituminous outside coating.

B. Ductile iron pipe shall be manufactured in accordance with AWWA C151. All pipe, except specials, shall be furnished in nominal lengths of 18 to 20 feet. Sizes will be as shown on the Drawings. All pipe shall have a minimum pressure rating

02730-3 as indicated in the following table, and corresponding minimum wall thickness, unless otherwise specified or shown on the Drawings:

Pipe Sizes (inches)

Pressure Class (psi)

4 - 12 350

16 - 24 250

C. Flexible Joint (Ball Joint) Pipe: Flexible, restrained joint pipe shall be minimum

Thickness Class 56. Appropriate transition pieces shall be utilized on each end of run of flexible joint pipe.

D. Fittings and Accessories

1. Fittings shall be ductile iron and shall conform to AWWA C110/ANSI

A21.10 or AWWA C153/ANSI A21.53 with a minimum rated working pressure of 250 psi, and shall be furnished with a bituminous outside coating.

2. Thrust Collars: Thrust collars shall be welded-on ductile iron body type capable of withstanding a thrust due to 250 psi internal pressure on a dead end from either direction on that pipe size. Weld-on collars shall be continuously welded to the pipe by the pipe manufacturer.

3. Solid Sleeves: Solid sleeves shall permit the connection of plain end ductile iron pipe and plain end PVC pipe. Solid sleeves shall meet the requirements of ANSI/AWWA C110 for long pattern and have a minimum pressure rating of 250 psi. Solid sleeves shall have a mechanical or restrained joint as specified in this Section and as shown on the Drawings. Solid sleeves shall be provided with gaskets suitable for the type of pipe to be connected. Solid sleeves shall be used only in locations shown on the Drawings or at the direction of the County. Solid sleeves shall be manufactured by ACIPCO, U.S. Pipe or McWane (Clow).

02730-4

E. Joints for Ductile Iron Pipe and Fittings

1. General

a. Joints for ductile iron pipe and fittings shall be mechanical joint, flanged joint, ball joint, restrained joint, or push-on joint as shown on the Drawings or specified herein.

b. Unless otherwise shown on the Drawings, specified or directed, all ductile iron pipe laid underground shall be joined using push-on type joints.

c. In all cases, gaskets shall be made of material that will not be damaged by the fluid being transported nor by the environment in which the pipe is installed.

d. Provide the necessary bolts for connections. All bolts and nuts shall be threaded in accordance with ANSI B1.1, Coarse Thread Series, Class 2A external and 2B internal fit. All bolts and nuts shall be made in the U.S.A.

2. Mechanical Joints

a. Joints shall conform to AWWA C111/ANSI A21.11.

b. Bolts and nuts shall be Tee Head Bolts and nuts of high strength low-alloy steel in accordance with ASTM A 242 to the dimensions shown in AWWA C111/ANSI A21.11.

c. Gaskets shall be in accordance with AWWA C111/ANSI A21.11 and shall be constructed of plain rubber.

d. Mechanical joint glands shall be ductile iron.

3. Push-On Joints: Push-on joints and gaskets shall conform to AWWA

C111/ANSI A21.11. Details of the joint design shall be in accordance with the manufacturer's standard practice such as ACIPCO "Fastite", McWane (Clow) "Bell-Tite", or U.S. Pipe "Tyton" joints.

4. Flanged Joints

a. Flanged joints shall conform to AWWA C115/ANSI A21.15. Flanges shall be ductile iron and shall be furnished by the pipe manufacturer.

b. Gaskets shall be made of 1/8-inch thick, cloth reinforced rubber.

Gaskets may be ring type or full face type.

c. Flanged ductile iron pipe shall have flanges cast solidly or threaded to the pipe barrel. Pipe threads shall be of such length that with flanges screwed home, the end of the pipe shall project beyond the face line of

02730-5 the flange. Flange and pipe shall then be machined to give a flush finish to the pipe and the flange and surface shall be normal to the axis of the pipe. Ductile iron flanges shall be of such design that the flange neck completely covers the threaded portion of the pipe to protect same against corrosion. All pipe with threaded type flanges shall be assembled, faced, and drilled at the point of manufacture, unless otherwise approved by the County.

d. Flange filler shall conform to AWWA C110/ANSI A21.10. Joint bolt length shall be increased by the thickness of the flange filler.

e. Where tap or stud bolts are required, flanges shall be drilled and tapped accordingly.

f. Bolt length and diameter shall conform to ANSI/AWWA C115 for Class 125 flanges shown in ANSI/ASME B16.1.

g. Bolts for exposed service shall be zinc plated, cold pressed, steel machine bolts conforming to ASTM A 307, Grade B. Nuts for exposed service shall be zinc plated, heavy hex conforming to ASTM A 563.

Zinc plating shall conform to ASTM B 633, Type II.

h. Bolts for submerged service shall be stainless steel machine bolts conforming to ASTM A 193, Grade B8. Nuts shall be heavy hex, stainless steel conforming to ASTM A 194, Grade 8.

5. Restrained Joints

a. Restrained joints shall be ACIPCO "FLEX-RING" or "FAST-GRIP", or U.S. "TR-FLEX" or "FIELD LOK".

b. Bolts and nuts shall be in accordance with the manufacturer's recommendations.

c. Gaskets shall be in accordance with the manufacturer's recommendations.

F. Interior Lining: Ductile iron pipe and fittings shall be lined with polyethylene, polyurethane or epoxy, as specified below:

1. Linings shall cover all exposed surfaces of pipe and fittings subject to contact with sewer liquid or gas. The lining of the pipe barrel shall extend from spigot end through the socket to the edge of the gasket sealing area or recess for pipe using push-on gaskets, and to the edge of the gasket seat for mechanical joints. The lining shall also cover the exterior of the spigot end from the end of the pipe to beyond the gasket sealing area. The lining in fittings shall cover the interior surfaces including the socket areas as defined above. All linings shall be hermetically sealed at the ends.

02730-6

2. Lining Materials

a. Polyethylene lining material for pipe barrel shall conform to ASTM D

1248, compounded with an inert filler and with sufficient carbon black to resist ultraviolet rays during aboveground storage. The polyethylene shall be bonded to the interior of the pipe or fitting by heat. Lining material for exterior of spigot and interior of socket shall be equal to Roskote Mastic B-151 or Madewell 1104 Coal Tar Epoxy.

Polyethylene lining system shall be ACIPCO Polybond or U.S. Pipe Polylined.

b. Polyurethane lining material shall consist of a two-part polyurethane coating system conforming to ASTM D 16, Type V, consisting of a polyisocynate resin and a polyol resin. Polyurethane for pipe barrel and fittings shall be Corropipe II Wasteliner as manufactured by Madison Chemical Industries, Inc. Polyurethane lining material for exterior of spigot and interior of socket shall be equal to Corropipe 'S' as manufactured by Madison Chemical Industries, Inc. Polyurethane lining system shall be equal to U.S. Pipe Polythane.

c. Epoxy: The lining material shall be Protecto 401 Ceramic Epoxy, a two component, modified epoxy formulated for corrosion control with the following minimum requirements:

(1) A permeability rating of 0.0 perms when measured by ASTM E 96, Procedure A. Duration of test shall be six weeks.

(2) A direct impact resistance of 125 inch-pounds with no cracking when measured by ASTM D 2794.

(3) The ability to build at least 50 mils dry in one coat.

(4) The material shall be recoatable with itself for at least seven days with no additional surface preparation when exposed to direct summer sun and a temperature of 90 degrees F.

(5) The material shall contain at least 20 percent by volume of ceramic quartz pigment.

(6) A test and service history demonstrating the ability of the material to withstand the service expected.

(7) Possess a minimum solids volume content of 88 percent, + one percent.

(8) Possess a maximum drying time to allow recoating as follows:

50 degrees F - 72 hours; 75 degrees F - 18 hours; 90 degrees F - 8 hours. If recoating cannot be accomplished within seven days, a light brush blast shall be performed to improve intercoat adhesion.

02730-7

3. All surfaces to be lined with polyethylene shall be blast cleaned equal to the requirements of SSPC-SP6. All surfaces to be lined with polyurethane shall be blast cleaned equal to the requirements of SSPC-SP10. All surfaces to be lined with epoxy shall be blasted and cleaned to remove all loose laitance, scale, or other loose material. No lining shall take place over grease, oil, etc., that would be detrimental to the adhesion of the compound to the substrate.

4. Application

a. Lining of pipe barrel and fittings shall be 40 mils nominal thickness;

minimum lining thickness shall be 30 mils. Lining thickness for exterior of spigot and interior of socket shall be 8 to 10 mils.

b. The lining shall be applied using a centrifugal lance applicator by applicators certified by the lining manufacturer. The workers shall be experienced and competent in the surface preparation, application and inspection of the lining to be applied. The compound shall not be applied when the substrate temperature is below 40 degrees F or in adverse atmospheric conditions which will cause detrimental blistering, pinholing or porosity of the film.

5. All pipe and fitting linings shall be tested for pinholes in accordance with ASTM G 62, Method B and shall be holiday free.

6. All pipe linings shall be checked for thickness using a magnetic film thickness gauge.

7. Each pipe joint and fitting shall be marked with the date of application of the lining system and with the numerical sequence of application of that date.

G. Polyethylene Encasement: Where shown on the Drawings, ductile iron pipe shall be encased with polyethylene film. Polyethylene film shall have a minimum thickness of 8 mils.

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2.02 POLYVINYL CHLORIDE (PVC) GRAVITY SEWER PIPE

A. Acceptability of PVC pipe for gravity sewers is indicated in the following table:

Standard Min Thick Type

PVC1

Wall

Acceptable

Manufacturers

< 6

8 to

ASTM D

SDR 35

12454B

SW Open

Yes Yes No No No

ASTM

F-679

SW Open

No No Yes Yes Yes

ASTM F

Series 46 12454C

OP Ultra-Rib

No No No No Yes

ASTM F

Series 46 12454C

CP Vylon Yes No No No Yes

1As specified in ASTM D 1784

SW Solid Wall OP Open Profile CP Closed Profile

Open shall mean any manufacturer whose products meet the specified standard is acceptable.

B. All pipe shall have a minimum pipe stiffness of 46 psi at five percent deflection as determined by ASTM D 2412.

C. PVC gravity sewer pipe shall be supplied in lengths not longer than 13 feet.

02730-9

D. Each length of pipe shall be marked with the manufacturer's name, trade name, nominal size, class, hydrostatic test pressure, manufacturer's standard symbol to signify it was tested, and date of manufacture. Each rubber ring shall be marked with the manufacturer's identification, the size, the year of manufacture, and the classes of pipe with which it can be used.

E. Fittings 15 inches in diameter and less shall be manufactured in accordance with

ASTM D 3034. PVC compound shall be 12454B or 12454C as specified in ASTM D 1784.

1. For sizes 8-inches and less in diameter, fittings shall be molded in one-piece with no solvent welded joints. Minimum socket depths shall be as specified in ASTM D 3034, Table 2.

2. For sizes 10-inches and larger in diameter, fittings shall be fabricated from pipe conforming to ASTM D 3034 using solvent welding. No field fabrication of fittings will be allowed. All such fabrication shall be performed at the factory and the fittings shall be delivered ready for use.

F. Joints: Joints for pipe and fittings shall be of the integral bell and spigot type with a confined elastomeric gasket having the capability of absorbing expansion and contraction without leakage, when tested in accordance with ASTM D 3212.

Gaskets shall meet the requirements of ASTM F 477. The joint system shall be subject to the approval of the County and shall be identical for pipe and fittings.

G. Manhole Connections

1. Solid Wall and Closed Profile Wall Pipe: The sewer shall be connected to manholes utilizing a standard pipe section.

2. Open Profile Wall Pipe: The sewer shall be connected to manholes with an adapter piece. The adapter piece shall have an open profile pipe bell and a solid wall pipe spigot for penetrating the manhole wall.

H. Acceptance: Acceptance will be on the basis of the County's inspection and the manufacturer's written certification that the pipe and fittings were manufactured and tested in accordance with the applicable standards.

2.03 MANHOLES AND PRECAST CONCRETE PRODUCTS

A. Provide manholes and other precast concrete products, including pumping station

02730-10 wetwell and valve vault, in accordance with the following:

1. Precast Concrete Sections

a. Precast concrete sections shall meet the requirements of ASTM C 478.

The minimum compressive strength of the concrete in precast sections shall be 4,000 psi.

b. The minimum wall thickness shall be one-twelfth of the inside diameter of the base, riser or the largest cone diameter. Additionally, the wall thickness shall be sufficient for the proper installation of the rubber boots.

c. Transition slabs which convert bases larger than four feet in diameter to four foot diameter risers shall be designed by the manhole manufacturer to carry the live and dead loads exerted on the slab.

d. Seal joints between precast sections by means of rubber O-ring gaskets or flexible butyl rubber sealant. Butyl rubber sealants shall meet the requirements of AASHTO M-198. Sealant shall be pre-formed type with a minimum nominal diameter of 1-inch. Butyl rubber sealant shall be equal to Kent Seal No. 2 or Concrete Sealants CS202.

e. Precast manhole bases, excluding pumping station wetwells and valve vaults, shall be provided with a minimum 8-inch wide extension.

2. Brick and Mortar: Brick shall be whole and hardburned, conforming to

ASTM C 32 Grade MS. Mortar shall be made of one part Portland cement and two parts clean sharp sand. Cement shall be Type 1 and shall conform to ASTM C 150. Sand shall meet ASTM C 144.

3. Iron Castings

a. Cast iron manhole frames and covers shall meet the requirements of ASTM A 48 for Class 30 gray iron and all applicable local standards.

All castings shall be tough, close grained, smooth and free from blow holes, blisters, shrinkage, strains, cracks, cold shots and other imperfections. No casting will be accepted which weighs less than 95 percent of the design weight. Shop drawings must indicate the design weight and provide sufficient dimensions to permit checking. All castings shall be thoroughly cleaned in the shop and given two coats of approved bituminous paint before rusting begins.

b. Manhole frames and covers shall be as shown on the Standard Detail Drawings.

c. All frames and covers shall have machined horizontal bearing surfaces.

d. All manholes shall have standard frames and covers except where

02730-11 specifically shown otherwise on the Drawings.

4. Rubber Boots: Provide preformed rubber boots and fasteners equal to those manufactured by Kor-N-Seal or Press Seal Gasket Corporation.

5. Interior Lining

a. Precast concrete, wetwells, drop manholes and air release valve manholes shall be lined (interior) with Protecto 401 Ceramic Epoxy or Corropipe II Wasteliner as manufactured by Madison Chemical Industries, Inc., or Agru Sure-Grip HDPE/PP-R concrete protective liner. Standard precast concrete manholes and valve vaults shall be lined (interior) with a coal tar epoxy equal to Carboline (Kop-Coat) Bitumastic 300M.

b. Surface Preparation and Application: After the manhole has cured, the equivalent of seven days at 77 degrees F, the interior of the manhole exposed to liquids and gases shall be blasted and cleaned to remove all loose laitance, form oil, or other loose material. After cleaning, the lining material shall be applied to yield 40 mils for the complete system using a centrifugal lance applicator. No lining shall take place over grease, oil, etc., that would be detrimental to the adhesion of the compound to the substrate. The compound shall not be applied when the substrate temperature is below 40 degrees F or in adverse atmospheric conditions which will cause detrimental blistering, pinholing or porosity of the film. In no case shall the lining be applied when the concrete surface is above 14 percent moisture content. The lining shall be applied by applicators certified by the lining manufacturer. The workers shall be experienced and competent in the surface preparation, application and inspection of the lining to be applied.

c. Inspection

(1) All manholes shall be checked for thickness using a magnetic film thickness gauge on metal coupons attached to five percent of the manhole coated.

(2) All manholes shall be pinhole detected with a non-destructive 2,500 volt test.

(3) Each manhole section shall be marked with the date of application of the lining system and with its numerical sequence of application of that date.

d. Handling: Equipment used to handle and transport the lined manholes

02730-12 shall be suitably designed and operated not to damage the lining. Any damage which occurs shall be repaired prior to the installation of the manholes in accordance with the manufacturer's recommendations, so the repaired area is equal to the undamaged lining and coating in all respects.

e. Joints: All surfaces in the joint areas that are concrete and that are in contact with the sewer liquids and gases shall be prepared for coating and coated as specified for the manhole. Any area in the joint area that is not smooth shall be made so using a quick setting epoxy grout. Care shall be exercised so that all areas exposed to the sewer liquids and gases are coated.

f. Lining shall be applied at the point of manufacture of the manhole and precast concrete product.

6. Exterior Coating

a. The exterior of manholes, wetwells and valve vaults shall be coated with a product as specified in Paragraph 5. above or with Farbertite, as manufactured by Briggs Bituminous Composition Company of Philadelphia, PA.

b. Surface preparation, application, inspection, handling and joints shall be as specified in Paragraph 5. above.

c. Coating shall be applied at the point of manufacture of the manhole and precast concrete product.

7. Aluminum Floor Doors

a. Door shall be a single or double leaf type as shown on the Drawings built to withstand 150 pounds per square foot.

b. The frame shall be 1/4-inch extruded aluminum with built-in neoprene cushion and with strap anchors bolted to the exterior. Door leaf shall be 1/4-inch aluminum diamond plate reinforced with aluminum stiffeners as required. Stainless steel hinges shall be bolted to the underside and pivot on torsion bars that counterbalance the door for easy operation.

The door shall open to 90 degrees and lock automatically in that position. A vinyl grip handle shall be provided to release the cover for closing. Doors shall be equipped with a snap lock and removable handle. Bituminous coating shall be applied to the exterior of the frame by the manufacturer. All hardware shall be stainless steel.

c. Door shall be Type S1R (single door) or S2R (double door), manufactured by Halliday or Type E, manufactured by Washington Aluminum Company.

02730-13

8. Sand-Cement Grout

a. Column baseplates, pipe support baseplates, tanks and miscellaneous small items of equipment shall be grouted in place using a sand-cement grout consisting of one part Portland cement, two parts fine aggregate and a maximum of 4.5 gallons of water per sack (cubic foot) of cement.

Portland cement shall be Type III conforming to ASTM C 150. Fine aggregate shall be natural siliceous sand, consisting of hard, clean, sharp, dense, durable and uncoated particles.

b. Fine aggregate shall be free from organic material and injurious amounts of deleterious substances and shall be graded as follows:

Sieve Size No.

Percent (by weight) Passing

4 100

8 95 - 100

16 60 - 100

30 35 - 70

50 15 - 35

100 2 - 15

c. Except as modified herein, fine aggregate shall conform to the requirements of ASTM C 144.

d. Fine aggregate to be used with epoxy binders shall be dried prior to use to remove any free moisture.

9. Non-Shrink Grout: All pumps, compressors, motors and other heavy equipment items shall be grouted in place with a nonmetallic, noncorrosive, nongaseous, nonshrink grout requiring no cutback or protective coating.

Nonshrink grout shall show zero shrinkage from the placement volume or initial expansion volume as determined by ASTM C 827, and shall have an initial set time at 70 degrees F of not less than 45 minutes as determined by ASTM C 191. When tested in accordance with ASTM C 109, nonshrink grout shall have a one-day compressive strength of not less than 2,000 psi and

02730-14 a 28-day compressive strength of not less than 9,000 psi at a flow of not less than 100 percent determined in accordance with Corps of Engineers Specification CRD-C-621. The grout shall contain no corrosive irons, calcium chloride, oxidizing catalysts, gas-forming agents, harmful aluminums or corrosive chemicals and shall be resistant to oil, water and sewage. The grout shall be premixed and shall require only the addition of water prior to placement. The grout shall be delivered to the job site in unopened, plastic-lined bags and shall have the manufacturer's mixing instructions printed on the back of each bag. Nonshrink grout shall be EUCO N-S Grout as manufactured by the Euclid Chemical Company, Masterflow 713 Grout as manufactured by Master Builders Company, or Upcon High Flow Grout as manufactured by UPCO Division of Emhart Chemical Company.

2.04 MISCELLANEOUS ACCESSORIES

A. Flexible Adaptor Couplings

1. Couplings for pipe sizes 15-inches in diameter and less shall be elastomeric plastic sleeves designed to connect pipes of dissimilar materials. Adapters shall provide a positive seal against infiltration and exfiltration and remain leakproof and rootproof up to 4.3 psi. The adaptor manufacturer shall provide all stainless steel clamps and required accessories.

2. Couplings shall be products of Fernco and shall be installed in accordance with the manufacturer's recommendations.

B. Flexible Adaptor Donuts

1. Adaptor donuts shall be elastomeric polyvinyl chloride (PVC), compressible seals designed for sealing joints between sewer pipes of different sizes and/or dissimilar materials. Adaptors shall provide a positive seal against infiltration and exfiltration and remain leakproof and rootproof up to 4.3 psi.

2. Donuts shall be products of Fernco and shall be installed in accordance with the manufacturer's recommendations.

C. Detection Tape and Tracer Wire: Detection tape shall be composed of a solid aluminum foil encased in a protective plastic jacket. Tapes shall be color coded in accordance with APWA color codes with the following legends: Sanitary Sewerage Systems, Safety Green, "Caution: Sewer Line Buried Below". Colors may be solid or striped. Tape shall be permanently printed with no surface printing allowed. Tape width shall be minimum 2-inches when buried less than 10-inches

02730-15 below the surface. Tape width shall be minimum 3-inches when buried greater than 10-inches and less than 20-inches. Detection tape shall be equal to Lineguard Type III Detectable or Allen Systems Detectatape. In addition, prior to backfill of trench the Contractor shall furnish and install 14 gauge coated copy wire. The wire shall be installed along the pipe during the backfill operation. Wire shall be brought up at each manhole.

D. Raised Pavement Markers: Raised pavement markers shall meet the specifications and requirements set forth in the most current edition of the State of Georgia Department of Transportation “Standard Specifications for the Construction of Roads and Bridges”, Section 654.

E. Backwater Valves: It is recommended that a backwater valve be placed on all service connections to prevent backflow or waste from street sewers. Backwater Valves to include elastomeric seal in quick action flapper to ensure a water tight seal, threaded access cap with neoprene seal for positive sealing as well as a valve hub to fit DWV pipe of which can be adapted for sewer and drain pipe.

PART 3 EXECUTION

3.01 LOCATION AND GRADE

A. The Drawings show the alignment and grade of the gravity sewer and the position of manholes and other appurtenances. The slope shown on the gravity sewer profile and/or called for in the Specifications is the slope of the invert of the pipe.

B. After the Contractor locates and marks the manhole centerlines or baselines of the gravity sewer, the Contractor shall perform clearing and grubbing.

3.02 LAYING AND JOINTING PIPE AND ACCESSORIES

A. Lay all pipe and fittings to accurately conform to the lines and grades established by the construction drawings.

B. Pipe Installation

1. Proper implements, tools and facilities shall be provided for the safe performance of the Work. All pipe, fittings and valves shall be lowered carefully into the trench by means of slings, ropes or other suitable tools or equipment in such a manner as to prevent damage to sewer materials and

02730-16 protective coatings and linings. Under no circumstances shall sewer materials be dropped or dumped into the trench.

2. All pipe, fittings, valves and other appurtenances shall be examined carefully for damage and other defects immediately before installation. Defective materials shall be marked and held for inspection by the County, who may prescribe corrective repairs or reject the materials.

3. All lumps, blisters and excess coating shall be removed from the socket and plain ends of each pipe, and the outside of the plain end and the inside of the bell shall be wiped clean and dry and free from dirt, sand, grit or any foreign materials before the pipe is laid. No pipe which contains dirt shall be laid.

4. Foreign material shall be prevented from entering the pipe while it is being placed in the trench. No debris, tools, clothing or other materials shall be placed in the pipe at any time.

5. As each length of pipe is placed in the trench, the joint shall be assembled and the pipe brought to correct line and grade. The pipe shall be secured in place with approved backfill material.

6. It is common practice to lay pipe with the bells facing the direction in which work is progressing.

7. Applying pressure to the top of the pipe, such as with a backhoe bucket, to lower the pipe to the proper elevation or grade shall not be permitted.

8. Polyethylene Encasement: Installation shall be in accordance with AWWA

C105 and the manufacturer's instructions. All ends shall be securely closed with tape and all damaged areas shall be completely repaired to the satisfaction of the County.

C. Alignment and Gradient

1. Lay pipe straight in alignment and gradient or follow true curves, where shown on the Drawings, as nearly as practicable. Do not deflect any joint more than the maximum deflection recommended by the manufacturer.

2. Maintain a transit, level and accessories on the job to lay out angles and ensure that deflection allowances are not exceeded.

3. The Contractor shall check the invert elevation at each manhole and the

02730-17 gravity sewer invert elevation at least three times daily, start, mid-day and end of day. Elevations shall be checked more frequently if more than 100 feet of pipe is installed in a day or if the gravity sewer is being constructed at minimum slope.

4. The Contractor shall check the horizontal alignment of the gravity sewer at the same schedule as for invert elevations.

D. Expediting of Work: Excavate, lay the pipe, and backfill as closely together as possible. Do not leave unjointed pipe in the trench overnight. Backfill and compact the trench as soon as possible after laying and jointing is completed. Cover the exposed end of the installed pipe each day at the close of work and at all other times when work is not in progress. If necessary to backfill over the end of an uncompleted pipe or accessory, close the end with a suitable plug, either push-on, mechanical joint, restrained joint or as approved by the County.

E. Joint Assembly: Push-on, mechanical, flange and restrained type joints shall be assembled in accordance with the manufacturer's recommendations.

F. Cutting Pipe

1. Cut ductile iron pipe using an abrasive wheel saw.

2. Cut PVC pipe using a suitable saw.

3. Remove all burrs and smooth the end before jointing.

4. The Contractor shall cut the pipe and bevel the end, as necessary, to provide the correct length of pipe necessary for installing the fittings, valves, accessories and closure pieces in the correct location. Only push-on or mechanical joint pipe shall be cut.

G. House Connections: Install wyes or tees in locations designated by the County for future connection of service lines. Plug the branch of the wye or tee. Record the location of fittings installed on the Record Drawings.

3.03 CONNECTION TO AN EXISTING MANHOLE

Connection to an existing manhole shall be made by mechanically coring into the wall structure of the manhole. Cored opening shall be sized to properly accommodate a rubber boot seal as specified in this section.

02730-18

3.04 CONNECTION AND REPAIRS TO AN EXISTING SEWER MAIN

Where connections or repairs are required, Contractor shall only use solid sleeves and provide all materials and labor necessary to make the connection or repair to the existing pipeline, excluding service lines 6” or smaller.

3.05 MANHOLE AND PRECAST CONCRETE PRODUCT CONSTRUCTION

A. Construct manholes as shown on the Standard Detail Drawings.

B. Precast Concrete: Handle sections carefully to prevent cracking or chipping.

Provide uniform bedding of the bottom section to prevent uneven loading. Install gaskets and joint sealants in accordance with manufacturer's recommendations to produce a watertight structure.

C. Brick: Bed the bottom and sides of every brick in mortar. Apply a smooth coat of mortar, 3/4-inch thick, on the inside and outside.

D. Inverts: Form channels as shown on the Drawings, rounded, and troweled smooth.

Maintain consistent grade through the invert. Use sand-cement grout.

E. Top Elevations: Build manholes outside of paved areas to 18-inches above finished grade unless otherwise shown on the Drawings or directed by the County. Build manholes in paved areas to existing grades.

F. Drop Connections: Manholes requiring drop connections are shown on the

Drawings. Construct drop connections of the same materials as the upstream sewer and in accordance with the details shown on the Drawings.

G. Frames and Covers: Unless frame and cover is at grade, the frame shall be cast into the cone section.

H. Seal all manhole joints and lift holes, both inside and out, with grout. Between precast sections, this is in addition to joint sealant.

I. Invert Elevations: The invert elevations shown on the Drawings shall be for the invert at the centerline of the precast concrete manhole. Prior to setting the laser or other vertical alignment control system for the sewer upstream of the manhole, the Contractor shall verify the elevation of the sewer installed at the manhole.

J. Manholes shall be constructed such that their walls are plumb.

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K. Floor doors shall be integrally cast into the top slab, and shall be cast into the concrete in accordance with the manufacturer's recommendations.

3.06 CONCRETE COLLARS

Construct collars as shown on the Drawings.

3.07 DETECTION TAPE AND TRACER WIRE

Detection tape and tracer wire shall be provided over all sewers constructed by the open cut method, except those lengths of sewers directly underneath paved surfaces of County-owned roadways.

3.08 RAISED PAVEMENT MARKERS

Raised pavement markers (RPM’s) shall be provided and installed along the appropriate roadway centerline for each manhole not located within paved surfaces.

RPM’s for manholes shall be Type I, two-way, and green in color.

3.09 INSPECTION AND TESTING

A. Clean and flush lines prior to testing. Clean and test lines before requesting final acceptance. Where any obstruction is met, clean the sewers by means of rods, swabs, or other instruments. When requested by the County, flush out lines and manholes before final inspection.

B. Gravity Sewers: Pipe lines shall be straight and show a uniform grade between manholes. Correct any discrepancies discovered during inspection.

1. Infiltration Tests: Use only when groundwater is more than two feet above the top of the pipe.

a. Install suitable weirs in manholes selected by the County to determine the leakage of ground water into the sewer. The maximum length of line for each infiltration test shall be 5,000 feet. Measure leakage only when all visible leaks have been repaired and the ground water is two feet above the top of the pipe. If leakage in any section of the sewer line exceeds 100 gpd/inch diameter/mile, locate and repair leaks.

Repair methods must be approved by the County. After repairs are completed, re-test for leakage.

02730-20

b. Furnish, install, and remove the necessary weirs, plugs, and bulkheads required to perform the leakage tests. Where continuous monitoring of flow level is required, the County will provide and operate monitoring equipment.

2. Exfiltration Tests: Choose one of the following when groundwater is less than two feet above the top of the pipe.

a. Hydrostatic Test

(1) Test pipe between manholes with a minimum of 10 feet hydrostatic pressure, measured at the center of the pipe at the upstream manhole.

(2) The ends of the pipe in the test section shall be closed with suitable watertight bulkheads. Inserted into the top of each bulkhead shall be a 2-inch pipe nipple with an elbow. At the upper end of the test section, a 12-inch riser pipe shall be connected to the 2-inch nipple. The test section of pipe shall be filled through the pipe connection in the lower bulkhead which shall be fitted with a valve, until all air is exhausted and until water overflows the riser pipe at the upper end.

Water may be introduced into the pipe 24 hours prior to the test period to allow complete saturation. House service lines, if installed, shall also be fitted with suitable bulkheads having provisions for the release of air while the test section is being filled with water.

(3) During the test period, which shall extend over a period of two hours, water shall be introduced into the riser pipe from measured containers at such intervals as are necessary to maintain the water level at the top of the riser pipe. The total volume of water added during the test period shall not exceed that specified for infiltration.

b. Low-Pressure Air Test

(1) Prior to air testing, the section of sewer between manholes shall be thoroughly cleaned and wetted. Immediately after cleaning or while the pipe is water soaked, the sewer shall be tested with low-pressure air. At the Contractor's option, sewers may be tested in lengths between manholes or in short sections (25 feet or less) using inflatable balls pulled through the line from manhole to manhole. Air shall be slowly supplied to the plugged sewer section until internal air pressure reaches approximately 4.0 psi.

After this pressure is reached and the pressure allowed to stabilize

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(approximately two to five minutes), the pressure may be reduced to 3.5 psi before starting the test. If a 1.0 psi drop does not occur within the test time, then the line has passed the test. If the pressure drops more than 1.0 psi during the test time, the line is presumed to have failed the test, and the Contractor will be required to locate the failure, make necessary repairs, and retest the line. Minimum test time for various pipe sizes, in accordance with ASTM C 828 is as follows:

Nominal Pipe Size, inches

T (Time Min/100) Feet

6 0.7

8 1.2

10 1.5

12 1.8

15 2.1

18 2.4

21 3.0

24 3.6

(2) Required test equipment, including inflatable balls, braces, air hose, air source, timer, rotameter as applicable, cut-off valves, pressure reducing valve, 0-15 psi pressure gauge, 0-5 psi pressure gauge with gradations in 0.1 psi and accuracy of + two percent, shall be provided by the Contractor. Testing equipment shall be equal to Cherne Air-Loc Testing Systems.

(3) The Contractor shall keep records of all tests made. Copy of such records will be given to the County. Such records shall show date, line number and stations, operator, and such other pertinent information as required by the County.

(4) The Contractor is cautioned to observe proper safety precautions in performance of the air testing. It is imperative that plugs be properly secured and that care be exercised in their removal.

Every precaution shall be taken to avoid the possibility of over-pressurizing the sewer line.

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3. Deflection Test

a. Test PVC gravity sewer for excessive deflection by passing a mandrel through the pipe. Deflection of the pipe shall not exceed the following:

Nominal Pipe Diameter

Maximum Allowable Deflection

< 12-inches 5%

15 to 30-inches 4%

> 30-inches 3%

b. The mandrel size shall be based upon the maximum possible inside diameter for the type of pipe being tested, taking into account the allowable manufacturing tolerances of the pipe. The mandrel shall have an odd number of legs, or vanes, with a quantity of such equal to or greater than nine. The legs of the mandrel shall be permanently attached to the mandrel. A mandrel with variable sizes shall not be allowed. The mandrel shall be constructed of steel aluminum or other material approved by the County, and shall have sufficient rigidity so the legs of the mandrel will not deform when pulling through a pipe.

The mandrel dimensions shall be checked by the County before use by the Contractor.

c. Excavate and install properly any section of pipe not passing this test.

Re-test until results are satisfactory.

d. This test shall be performed within the first 30 days of installation and during final inspection, at the completion of this contract.

3. Closed Circuit Television: If deemed necessary by the County, the interior of the gravity sewers shall be subjected to a televised inspection. Prior to Final Acceptance the County shall be provided with one copy of the TV inspection report and video cassette showing the entire length of gravity sewer being tested. The report shall contain the condition of pipe, type of pipe, depth, location of services, length, type joint, roundness, and distance between manholes. Any pipe found to be cracked, leaking, misaligned, bellied or otherwise defective shall be removed and replaced.

C. Manholes: Prior to testing manholes for watertightness, all liftholes shall be plugged with a non-shrink grout, all joints between precast sections shall be

02730-23 properly sealed and all pipe openings shall be temporarily plugged and properly braced. Each manhole shall pass one of the following tests:

1. Exfiltration Tests: The manhole, after proper preparation as noted above, shall be filled with water. The maximum allowable leakage shall be eight gallons per foot of depth per 24 hours for 48-inch diameter manholes. Tests shall last a minimum of eight hours. The manholes may be backfilled prior to testing.

2. Vacuum Tests: The manhole, after proper preparation as noted above, shall be vacuum tested prior to backfilling. The test head shall be placed at the inside of the top of the cone section and the compression head inflated to 40 psi to effect a seal between the vacuum base and the manhole structure.

Connect the vacuum pump to the outlet port with the valve open. A vacuum of 10-inches of mercury shall be drawn and the vacuum pump shut off. With the valves closed, the time shall be measured for the vacuum to drop to 9-inches. The manhole shall pass if the time is greater than 60 seconds for 48-inch diameter manholes. If the manhole fails the initial test, necessary repairs shall be made with non-shrink grout while the vacuum is still being drawn. Retesting shall proceed until a satisfactory test is obtained. Vacuum testing equipment shall be equal to that as manufactured by P.A. Glazier, Inc.

D. Re-Testing: Any alterations made to pipeline or manholes performed after initial testing shall be re-tested and pass again, regardless of initial test results.

E. Notification: Lowndes County shall be notified 24-hours in advance prior to

Contractor performing any testing.

3.10 WETWELL LINERS

A. Products:

1. Epoxytec CPP by the Tnemec Company

2. Raven 405

B. Surface Preparation: Abrasive sandblast or high-velocity water jet, minimum 5,000 psi, to achieve a minimum CSP 4-5

C. Leaks: If water is detected after the surface prep, the general contractor and/or engineer will be notified. Epoxytec Mortartec Hydrxx 1 or Hydrxx 3 will rectify all areas of active leaks by sealing leaking joints and cracks in concrete structures or other approved materials.

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D. Exposed rebar:

1. Remove deteriorated or loose concrete surrounding the steel reinforcing bar

(rebar), including 3/4” around the entire circumference of the rebar, following ICRI guidelines No.310.1R.

2. Power tool clean all exposed rebar to a SSPC-SP11 standard

3. Apply 1 coat of Series 1 avoid spillage or application onto the parent concrete.

4. Build the substrate flush to the original concrete plane

E. Coating Application- Apply all coatings per manufacturer’s recommendations.

1. Skim coat (if needed):

a. Tnemec Epoxytec Mortartec Ceramico applied up to 1”

b. Tnemec Series 217 applied 1” to 4”

2. 1st Coat: Tnemec-Epoxytec CPP Trowel or Sprayliner applied at 150 mils minimum, OR

3. 1st Coat: Raven 405 applied at 150 mils minimum.

F. Warranty: At the completion of the job, a joint warranty will be issued to the owner.

This warranty includes a 10-year material replacement warranty from the manufacturer and a labor warranty from the qualified applicator. During the warranty period, the applicator will reinstall the coating system in the failed areas if any adhesion loss is detected.

3.11 PAINTING

A. Valve and metal pipe repainting

1. Surface Preparation: Abrasive sandblast to a SSPC-SP10 Near White Metal Blast standard. Before painting, the substrate must be clean, dry, and free of all contaminants.

2. 1st Coat: Tnemec Series 1 applied at 2-3 mils dry 2nd Coat: Tnemec Series N69F applied at 3-5 mils dry 3rd Coat: Tnemec Series N69F applied at 3-5 mils dry

END OF SECTION