B09_Amd8_-_Spec_33_31_11_-_GRAVITY_SEWER_PIPELINE___MANHOLE_INSTALLATION_0008.pdf

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GRAVITY SEWER PIPELINE AND MANHOLE

INSTALLATION

SECTION 33 31 11 - GRAVITY SEWER PIPELINE AND MANHOLE INSTALLATION

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes:

1. Installation and testing of sewer pipes, manholes, structures and appurtenances.

2. Connections to existing sewers.

3. Coordination and interface with existing facilities and utilities.

B. Related Specification Sections include but are not necessarily limited to:

1. Section 31 23 00 - Earthwork.

2. Section 31 23 33 - Trenching, Backfilling, and Compacting for Utilities.

3. Section 32 12 16 - Asphaltic Concrete Vehicular Paving.

4. Section 32 91 13 - Topsoiling and Finished Grading.

5. Section 33 05 16 - Precast Concrete Structures.

6. Section 33 05 26 – Utility Line Marking.

7. Section 33 75 00 – Temporary Bypass Pumping Systems.

1.2 QUALITY ASSURANCE

A. Referenced Standards:

1. ASTM International (ASTM):

a. C1244, Vacuum Test

b. ASTME E1003, Manhole Hydrostatic Testing

c. D1784, Rigid Polyvinyl Chloride Compounds

d. D2122, Standard Test Method for Determining Dimensions of Thermoplastic

Pipe and Fittings

e. D3034, Polyvinyl Chloride Sewer Pipe and Fittings

f. F477, Elastomeric Seals (Gaskets) for Joining Plastic Pipe

g. F1417, Standard Practice for Installation Acceptance of Plastic Non-pressure Sewer Lines Using Low-Pressure Air.

2. Occupational Safety and Health Administration (OSHA).

1.3 ACTION SUBMITTALS

A. Shop Drawings:

1. Product technical data including:

a. Catalog data sheets for all pipe materials and tracer wire.

b. Details of all piping system components confirming that the pipe, fittings, and appurtenances conform to the specified requirements.

c. Manufacturers’ written recommendations for material handling, delivery, storage, installation, and minor repair of materials damaged in shipping.

2. Bypass pumping plan showing sequencing, routes, materials, and method of pumping.

3. Sanitary sewer service line plan showing alignment, cleanout location, slope and connection points for each service line.

4. Post installation CCTV videos of entire sewer main system.

B. Test Reports:

1. Submit results of leakage tests including the following:

a. Test procedure.

b. Pipeline segment tested.

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c. Length of pipe tested.

d. Test pressure.

e. Test duration

f. Amount of leakage.

g. Corrective action, if any.

2. Precast Concrete Mix Design

3. Compressive strength testing of cylinders

4. Deflection Test Results

5. Lamping Test Results

C. Certification by Manufacturer:

1. Manufacturer’s Certification for all pipe and fittings, certifying that the pipe and fittings meet the contract requirements.

1.4 DELIVERY, STORAGE, AND HANDLING OF PRODUCTS

A. In addition to the requirements specified in this section, see related paragraphs in individual pipe specifications.

B. Deliver, handle and store products in accordance with manufacturer's instructions.

Refer to Drawings for approved on-site laydown areas.

C. Protect pipeline sections stored at the site from damage.

D. Store all products above the ground upon platforms, pallets, skids, or other supports supplied by the Contractor.

1. Store in a way to permit ready access for identification and inspection by the

Contracting Officer.

E. Keep products free from dirt and other foreign matter.

F. Provide suitable quantities of all lifting equipment to handle the pipe.

1. Do not utilize any equipment that is not rated to handle the intended loading or conditions of use to which it will be subjected, or which will damage or gouge the pipe.

2. Do not drag or drop pipe.

G. Place pipe lain directly on the ground prior to placement on an area free of loose stones or sharp objects.

H. Repair or replace any new pipe and fittings damaged before or during installation at Contractor’s expense, before proceeding further.

1. Utilize repairs methods as recommended by the manufacturer.

2. Replace damaged materials as directed by Contracting Officer’s Representative.

I. Protect PVC pipe from UV degradation if stored outside for more than 60 days.

PART 2 - PRODUCTS

2.1 MATERIALS

A. General

1. Furnish sewer pipe and fittings as specified in the Contract Documents and meeting the materials and testing requirements of this Section. Furnish wye or tee branches and service line piping of the same material and design as the sewer pipe unless specified otherwise. Pipe classifications are shown on the Drawings and/or

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are listed in the Contract Documents.

2. References made to ASTM, ANSI or AASHTO designation are the latest revision at the time of call for bids.

3. Assure all pipe is clearly marked with type, class and/or thickness as applicable. Assure lettering is legible and permanent under normal conditions of handling and storage.

4. Furnish the joint type, class, thickness designation, castings, lining, marking, testing, etc. as specified.

B. Polyvinyl Chloride (PVC) pipe:

1. General:

a. Furnish PVC pipe produced by a continuous extrusion process, employing a prime grade of un-plasticized polyvinyl chloride. Assure the grade used is highly resistant to hydrogen sulfide, sulfuric acid, gasoline, oil, detergents and other chemicals found in sewage and industrial wastes.

Assure the material meets “Rigid Polyvinyl Chloride Compounds”, ASTM D-1784 requirements. Assure the pipe has self-extinguishing flammability characteristics.

2. Sewer Pipe:

a. Furnish sewer pipe meeting ASTM D3034, “Standard Specification for

Polyvinyl Chloride Sewer Pipe and Fittings”, SDR-35 rating for both sewer main and services.

b. Use a nominal laying length of 20 feet, except shorter lengths may be used adjacent to bends or other appurtenances. Assure each pipe length is marked, as a minimum, with size, SDR, pressure rating or both, ASTM designation and manufacturer’s name and code.

3. Pipe Jointing

a. Furnish each pipe length with a bell designed to provide a watertight joint when jointing the bell and spigot with an elastomeric ring (gasket) meeting ASTM designation F477.

b. Make a gasket joint for PVC pipe and fittings using a gasket compressed between the outer surface of the spigot and the inner surface of the bell.

Assure the joint is completely sealed by the gasket so that the assembly remains watertight under all service conditions, including expansion, contraction, settlement and pipe deformation. Follow the manufacturer’s recommendations when assembling the gasket.

4. Fittings:

a. Assure wye fittings for connecting service lines are of the same material, construction and joint design as the main sewer pipe.

5. Tracer Wire

a. Where indicated on the Drawings, tracer wire shall be installed in accordance with Section 33 05 26 – Utility Line Marking. Tracer wire shall only be installed on sewer service lines in accordance with the Drawings.

C. Manholes: See Section 33 05 16 – Precast Concrete Manholes.

D. Fill and Backfill at manholes: See Sections 31 23 00 and 31 23 33.

E. Embedment and Bedding Materials for pipelines: See Section 31 23 33.

F. Size mandrels to meet deflection requirements specified herein or in the individual pipe material specifications.

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PART 3 - EXECUTION

3.1 GENERAL REQUIREMENTS

A. Furnish all construction materials and equipment required for installation and backfill.

B. Install the pipeline complete, including bends, stop logs, and other associated work and appurtenances, as shown on the Drawings or as herein specified.

C. Make all necessary connections to sewer lines shown on the Drawings and in accordance with the Specifications.

D. Pipe shall be beveled in accordance with Manufacturer’s installation instructions. Use a factory- finished beveled end as a guide to determine the angle and length of taper.

Remove all burrs and raised edges prior to avoid cutting the gasket.

E. Construct all sewer piping, manholes, and structures to be free of visible ground water inflow.

1. Install sanitary sewer manholes and structures that are watertight.

a. Repair or replace any manhole or structure showing infiltration of ground water through joined surfaces, pipe to manhole/structure connections or manhole/structure wall.

2. Install pipe with watertight pipe joints.

F. Repair or replace any joint showing infiltration of ground water through pipe joints or pipe to manhole connections. Alignment: Lay gravity sewer lines in straight alignment and uniform grade between manholes.

1. Install at grade as shown on drawings.

G. Brace and protect pipe sections to prevent deformation during installation and backfill.

H. Deflection: Pipe deflection after final backfill shall not exceed the specified limits detailed in the individual pipe specifications.

1. Remove and replace any pipe observed to be deflecting in excess of the specified limits.

I. Perform testing in accordance with requirements of this Section.

J. Provide Contracting Officer and third party contractor with free access to work for inspection.

1. Such inspection shall not relieve the Contractor of his responsibility for performing

Work in accordance with the Contract Documents.

3.2 PIPELINE INSTALLATION

A. Lateral shoring of the trench walls or other similar construction methods may be required.

1. Design and implement all such methods.

2. When required, install shoring in accordance with all applicable local, State and OSHA regulations.

3. Remove shoring prior to backfilling.

B. Grade bottoms of trenches such that when bedding is placed between the trench bottom and the pipe, each section of pipe is installed to the specified depth or elevation with uniform support.

C. Pipe Depth

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1. Pipe shall be installed to match the depths and invert elevations shown in the construction drawings, with any deviations requiring Engineer approval.

D. Determine and fix alignment and grade or elevation of each pipeline from offset stakes and/or calibrated laser instruments.

E. Install pipelines on the line and grade shown on Drawings.

1. Calculate required elevation of each pipe joint and survey installed elevation at each joint prior to stabbing the next joint to verify grade.

2. Adjust pipe to proper grade if any joint elevation deviates from the calculation by more than 0.01 FT.

F. Remove material at the bottom of the trench if determined to be unsuitable by the Contracting Officer.

1. Backfill trench with approved subgrade material or bedding material to the specified depth or elevation as described in Section 31 23 33.

G. Install only clean pipe and fittings.

1. Provide physical barriers to protect open ends of sections of pipe in place from the entrance of trench water, mud, dirt, or other foreign substances with when pipe installation is not in progress.

H. Begin pipe laying at the lowest elevation with bell ends facing the direction of laying, except when reverse laying is permitted by Contracting Officer.

I. Where the drawings require concrete encasement or flowable fill embedment and backfill, anchor pipe as required to prevent floatation.

1. Alternatively, Contractor may place concrete or flow fill materials in staged lifts allowing each lift to reach initial set prior to placing the subsequent lift to limit buoyancy effects and prevent floatation of the pipeline.

J. Pipeline may be backfilled as it is installed, provided all inspection and testing requirements are met.

K. Pipe, fittings, and special pieces will be subject to inspection by CO, prior to installation.

1. Report all damages not detected by CO but discovered by Contractor during installation to CO for corrective action or replacement.

L. Repair of pipe damaged during installation shall conform to the manufacturer’s repair procedures, with the concurrence of CO.

3.3 RESTORATION

A. Restore all existing structures or services damaged by Contractor's operations at no cost to the CO.

1. Repair or replace culverts that are damaged, removed or interfere with the work as part of restoration at no additional cost to CO.

B. Driveway Removal and Replacement:

1. All Portland cement concrete and asphalt noted for removal and replacement shall be cut prior to removal.

a. Cut by sawing, vertical cut to be 1 IN minimum.

b. The remaining depth of section may be broken out in a manner subject to CO’s approval.

c. Width of section removed to be either a width not greater than the outside

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diameter of the sewer plus 4 FT-0 IN or broken out to the nearest joint.

2. Replace Portland cement concrete and asphalt equal to or better than original paving.

3. Debris resulting from the above operations shall be removed and disposed offsite.

4. Include driveway removal and replacement in cost of the bid unit price of the sewer pipe.

C. Gravel Surfaced Drives and Roadways:

1. Restore all damaged gravel surfaced drives and roadways to a condition equal to or better than original.

D. Trees:

1. Do not remove trees without written instructions from the Contracting Officer.

E. Fences, Signs, Mailboxes, etc.:

1. Restore all damaged fences, signs, mailboxes, etc., to their original conditions.

a. No separate payment will be made for these items.

3.4 PROTECTION OF EXISTING UTILITIES

A. Verify the location of all underground utilities.

1. Omission from, or the inclusion of utility locations on the plans is not to be considered as the nonexistence of or a definite location of existing underground utilities.

B. Notify utility representative prior to construction to obtain available information on location of existing utilities.

1. Contractor shall be responsible for locating all utilities.

C. Notify representative of the underground utilities 24 HRS in advance of crossings.

D. Existing water services and sewer services:

1. Repair damage to existing water service using copper pipe and union the same size as existing service.

3.5 FIELD QUALITY CONTROL

A. General Testing Requirements:

1. Furnish necessary personnel, materials, and equipment, including bulkheads, restraints, anchors, temporary connections, pumps, water, pressure gauges, and other means and facilities required to perform tests.

2. Obtain CO approval of methods and the equipment used for the tests prior to testing.

3. Provide reasonable facilities and access for CO to inspect, test and obtain such information as required with respect to the materials used and the progress and condition of the Work and the results obtained.

a. Work that is not performed in accordance with the procedure or does not comply with the requirements of the Specifications will be rejected.

4. Coordinate testing schedules with CO.

a. Perform all specified tests under observation of CO.

b. Provide a minimum of 24 HRS advance notice prior to commencing any testing.

5. Perform testing as work progresses and as required to facilitate connections with existing sewers.

6. Obtain water for testing and cleaning at no additional cost to the CO.

7. Test only those portions of pipes that have been installed as part of this Contract.

a. Test new pipe sections prior to making final connections to existing piping.

b. Furnish and install plugs, bulkheads, and restraints required to isolate new pipe sections.

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8. Unsuccessful Tests:

a. Where tests are not successful, correct defects or remove defective piping and appurtenances and install piping and appurtenances that comply with the specified requirements.

b. Repeat testing until tests are successful at no additional cost to the CO.

9. Deflection:

a. Check each section of pipe after backfilling for deflection by pulling a mandrel through the pipe.

b. Maximum long-term deflection: less than 5% of the initial diameter.

B. Lamping:

1. Install each section of sewer line between manholes to be straight and uniformly graded.

2. Each section will be lamped by Contractor after pipe installation and witnessed by CO.

3. Furnish suitable assistants, materials, and air monitoring to assist CO.

C. Low Pressure Air Testing:

1. Test all gravity sewer pipes with a low-pressure air test.

a. Comply with ASTM F1417.

b. Time elapsed for a 1 PSI drop in air pressure: Per ASTM F1417.

c. Maximum air loss: Per ASTM F1417.

2. Submit schedule to CO for approval prior to starting the tests.

3. Conduct air test after the final backfill has been in place for a minimum of 30 days.

4. Correct pipes failing air test and conduct second test after final backfill has been in place an additional 30 days.

5. If the length of sewer to be tested is fully or partially submerged in groundwater, increase test pressure as necessary to overcome the actual static pressure exerted by the groundwater.

a. If a test pressure greater than 8 psi results, utilize water infiltration testing in lieu of air testing.

6. Locate leaks by testing short sections of pipe.

a. Repair leaks and retest affected reach of sewer.

D. Deflection Testing: Test all flexible sewer pipes for deflection.

1. Perform the mandrel test with the CO in observance for all pipe sizes.

2. Deflection limits: as indicated in the individual pipe sections or as specified in article titled “General Testing Requirements” above, whichever is more stringent.

3. Conduct test after the final backfill has been in place at least 30 days.

4. Correct pipes failing deflection test and conduct second test after final backfill has been in place an additional 30 days.

E. Deflection Testing: The Contracting Officer or their Representative may require deflection testing of all or any portion of a flexible pipe installation to assure the construction quality. Flexible pipe is pipe that will deflect at least 2 percent without any sign of structural distress.

1. Conduct deflection tests, when performed on PVC pipe, meeting ASTM D3034 and satisfy either of the following deflection limitations:

Minimum Period Between Trench Backfilling & Testing

Minimum Mandrel Diameter as a Percent of Inside Pipe

Diameter

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7 Days 95.0

30 Days 92.5

2. If deflection exceeds the specified limits, replacement or correction must be accomplished in accordance with requirements in the approved specifications.

3. The rigid ball or mandrel used for the deflection test must have a diameter of at least 95% or 92.5% (depending on the time of test) of the base inside diameter or average inside diameter of the pipe depending on which is specified in the ASTM Specification, including the appendix, to which the pipe is manufactured. The pipe must be measured in compliance with ASTM D2122 Standard Test Method of Determining Dimensions of Thermoplastic Pipe and Fittings. Mandrels must have at least nine arms. Perform the mandrel test without mechanical pulling devices.

F. Pipe Testing:

1. Conduct test after final backfill has been in place for at least 30 days.

2. Supply pressure gages of type, calibration, accuracy acceptable to the CO.

a. CO may request certification of the gages by a reliable testing firm and may compare these gages with a CO’ gage at any time.

3. Repair or replace pipes that do not pass joint test and retest.

a. Conduct retests after repairs have been made and final backfill has been in place for 30 days.

G. Manhole Testing:

1. Vacuum and/or hydrostatic test all manholes for leakage after installation, prior to being backfilled.

2. Visually inspect all manholes for leaks and defects prior to vacuum or hydrostatic testing.

3. Repair all leaks, defects or cracks discovered by visual inspection prior to vacuum or hydrostatic testing.

4. Seal all pipes entering manholes at a point outside the manhole walls so as to include testing of the pipe/manhole joints.

5. Make all necessary repairs and retest the manhole.

a. Inspect exterior of the manhole during this period for visible evidence of leakage.

b. All repairs will be subject to acceptance by the CO.

H. CCTV Inspection

1. The intent of this process is to inspect the interior of the completed line to determine the location of service taps and extent of omissions and/or any unacceptable work on the pipeline or manholes, such as sags, infiltration, gapped joints, protruding gaskets, etc. and provide a base reference for operations and maintenance.

2. Upon completion of the installation of new lines, including any appurtenances such as manholes and service connections, a CCTV camera shall traverse through each completed line segment.

3. The television camera used shall be one specifically designed and constructed for

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sewer inspection. Lighting for the camera shall be suitable to allow a clear picture of the entire periphery of the pipe. The camera shall be operative in 100 percent humidity/submerged conditions. The equipment will provide a view of the pipe ahead of the equipment and of features to the side of the equipment through turning and rotation of the lens. The camera shall be capable of tilting at right angles along the axis of the pipe while panning the camera lens through a full circle about the circumference of the pipe. The lights on the camera shall also be capable of panning 90 DEG to the axis of the pipe.

4. The radial view camera must be solid state color and have remote control of the rotational lens. The camera shall be capable of viewing the complete circumference of the pipe and manhole structure, including the cone-section. The camera lens shall be an auto-iris type with remote controlled manual override.

5. The video and audio recordings of the sewer inspections shall be made using digital video equipment. A video enhancer may be used in conjunction with, but not in lieu of, the required equipment. The digital recording equipment shall capture sewer inspection on USB drive, with each sewer segment (from upstream manhole to downstream manhole) inspection recorded as an individual file in MP4 with H.264 code format.

6. The system shall be capable of printing pipeline inspection reports with captured images of defects or other related significant visual information on a standard color printer. The system shall store digitized color picture images and be saved in digital format on a USB drive. The system shall be able to produce data reports to include, at a minimum, all observation points and pertinent data. The reports shall consist of condition observations recorded conforming to NASSCO and PACP codes. Camera footage, date & manhole numbers shall be maintained in real time and shall be displayed on the video monitor as well as the video character generators illuminated footage display at the control console.

7. CCTV video results shall be submitted to the Contracting Officer on a USB drive for review.

I. Leakage Test

1. New sewer line will not be finally accepted until leakage tests are made assuring the Contracting Officer that pipe laying and jointing are satisfactory.

J. Air-Test

1. Use the test procedure described below: Plug both ends of the pipe segment under test with airtight plugs and brace to prevent slippage and blowout. Furnish one plug with an inlet tap or other provision for connecting an air hose.

2. Equip the air supply hose, connected between the air compressor and the plug, with a throttling valve, an air bleed valve and a high-pressure shutoff valve for control. Equip the low-pressure side of the throttling valve with a tee for a monitoring pressure gauge, protected by a gauge cock. This cock is kept closed except when the pressure loss is being timed.

3. If the pipeline is submerged under groundwater, the back pressure, caused by the water head, is measured and added to the standard test pressures to compensate for the groundwater effect on the air test.

4. Apply air slowly to the pipeline until the pressure reaches 4.0 PSIG. Throttle the air supply to maintain the internal pressure between 4.0 and 3.5 PSIG for at least 2 MIN. During this time, check the plugs with soap solution to detect any plug leakage.

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5. When the pressure reaches exactly 3.5 PSIG, disconnect the air supply, start a stopwatch and record the time for the pressure to drop to 2.5 PSIG. The minimum time allowed for the pressure drop is computed on an air loss rate of 3.5 CFM or an air loss rate of 0.0030 CFM per square foot of inner pipe surface area under test, whichever rate yields the least time for the pressure drop. Should the time of the pressure drop between 3.5 and 2.5 PSIG be less than the allowable specified time, make the necessary leakage repairs and repeat the air test.

6. A nomograph which may be used to compute testing times for air testing is provided at the end of this Section. The nomograph computes results based upon English (U.S. Customary) units.

7. For single pipe size test sections, the length limits for minimum test times are contained in the following table.

LENGTH LIMIT FOR MINIMUM TEST TIMES

Pipe Diameter, IN

Test Section Length, FT

Minimum Maximum

4 642 1124

6 429 751

8 322 564

10 257 450

12 215 376

15 172 300

18 43 1250

21 123 215

24 107 188

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8. For test sections that are shorter than the minimum lengths, new test times must be calculated. This is done by multiplying the test time from the nomograph by the actual length of the test section (in feet) and then dividing the resultant product by the minimum test section length from the preceding table.

9. For test sections exceeding the maximum lengths, either shorten the test section to an allowable length or use the water test.

10. The nomograph shown will be used to compute the specification time even if several different pipe diameters are included in one test. Draw a straight line connecting the diameter on the “d” scale with the corresponding length of pipe of that diameter under test on the “L” scale. Each line will cross the “K” and “C” scales. The corresponding values of “K” and “C” for each diameter – length combination under test are read and recorded. All the “K” values are totaled, as are the “C” values. Total “K” governs if the total of “C” is less than 1.0 in which case, total “K” value equals the time in seconds that the pipeline under test should take before the pressure falls from 3.5 PSIG to 2.5 PSIG. If total “C” is greater than 1.0, total “K” is divided by total “C” to obtain the specification time in seconds.

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END OF SECTION 33 31 11