33 05 61 - Concrete Manholes and Inlets.pdf

33 05 61 - CONCRETE MANHOLES

Herbert, Rowland & Grubic, Inc. 33 05 61 - 1 000598.0465

SECTION 33 05 61 – CONCRETE MANHOLES

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes:

1. Modular precast Portland cement concrete manholes and precast polymer concrete manholes and structures with tongue-and-groove joints and transition to cover frame, covers, anchorage, and accessories.

2. Bedding and cover materials.

B. Related Requirements:

1. Section 03 10 00 - Concrete Forming and Accessories: Erection and bracing of forms.

2. Section 03 20 00 - Concrete Reinforcing: Reinforcing steel as required by this

Section.

3. Section 03 30 00 - Cast-in-Place Concrete: Concrete type for manhole and structure foundation slab construction.

4. Section 31 05 13 - Soils for Earthwork: Soils for backfill in trenches.

5. Section 31 05 16 - Aggregates for Earthwork: Aggregate for backfill in trenches.

6. Section 31 05 19.13 - Geotextiles for Earthwork: Filter fabric for subsurface drainage.

7. Section 31 23 16 - Excavation: Excavating for manholes, structures, and foundation slabs.

8. Section 31 23 23 - Fill: Backfilling after manhole and structure installation.

9. Section 33 05 05.36 - Vacuum Testing: Testing requirements for manholes.

10. Section 33 31 00 - Sanitary Sewerage Piping: Piping connections to manholes.

11. Section 33 42 00 - Stormwater Conveyance: Piping connections to manholes and structures.

1.2 DEFINITIONS

A. Bedding: Specialized material placed under manhole prior to installation and subsequent backfill operations.

1.3 REFERENCE STANDARDS

A. ASTM International:

1. ASTM C497 - Standard Test Methods for Concrete Pipe, Manhole Sections, or Tile.

2. ASTM C857 - Standard Practice for Minimum Structural Design Loading for

Underground Precast Concrete Utility Structures.

3. ASTM C913 - Standard Specification for Precast Concrete Water and Wastewater

Structures.

4. ASTM C923 - Standard Specification for Resilient Connectors between Reinforced

Concrete Manhole Structures, Pipes, and Laterals.

5. ASTM C990 - Standard Specification for Joints for Concrete Pipe, Manholes, and

Precast Box Sections Using Preformed Flexible Joint Sealants.

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6. ASTM F593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs.

1.4 SUBMITTALS

A. Section 01 33 00 - Submittal Procedures: Requirements for submittals.

B. Product Data: Submit manufacturer information for manhole covers, component construction, features, configuration, and dimensions.

C. Shop Drawings:

1. Submit a shop drawing for each proposed manhole structure.

2. Indicate structure locations and elevations.

3. Indicate sizes and elevations of piping and penetrations.

D. Certificates:

1. Manufacturer’s Certificate: Certify that products meet or exceed specified requirements.

2. PennDOT CS-430 form for all Precast Concrete Structures within the PennDOT right-of-way.

3. Pennsylvania Steel Products Procurement Act compliance certification.

4. Manholes: Certificate of construction compliance with ASTM C478.

E. QUALITY ASSURANCE

F. Structural Design Loading: Unless otherwise noted, utilities, structures and underground conveyance systems shall be constructed to withstand minimum loads in accordance with ASTM C857 with the following loading conditions, including impact load:

1. Heavy Traffic: ASTM C857; A-16, maximum 16,000 lb each wheel.

G. Source Quality Control:

1. Precast concrete unit manufacturer shall be listed in PennDOT Bulletin 15.

2. Precast concrete supplier plant shall be registered and certified under either the

Prestressed Concrete Institute (PCI) or the National Precast Concrete Association (NPCA) plant certification program.

3. Maintain uniform quality of products and component compatibility by using the products of one manufacturer in the case of precast reinforced concrete structures.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Section 01 61 00 - Product Requirements: Requirements for transporting, handling, storing, and protecting products.

B. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage.

C. Handling: Comply with precast concrete manufacturer instructions and ASTM C913 for unloading and moving precast manholes and drainage structures.

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D. Storage:

1. Store materials according to manufacturer instructions.

2. Store precast concrete manholes and drainage structures to prevent damage to

Owner's property or other public or private property.

3. Repair property damaged from materials storage.

E. Protection:

1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas.

2. Provide additional protection according to manufacturer instructions.

1.6 AMBIENT CONDITIONS

A. Cold Weather Requirements: Comply with ACI 530/530.1.

1.7 EXISTING CONDITIONS

A. Field Measurements:

1. Verify field measurements prior to fabrication.

2. Indicate field measurements on Shop Drawings.

PART 2 - PRODUCTS

2.1 PORTLAND CEMENT CONCRETE MANHOLES

A. Manufacturers:

1. Monarch Precast Concrete.

2. Terre-Hill Precast.

3. Or approved equal.

B. Manhole Sections:

1. Materials:

a. Reinforced Precast Concrete: Comply with ASTM C478 with 4,500 psi concrete. Cement shall be either:

1) ASTM C150, Type II – Moderate Sulfate Resistant Portland

Cement.

2) ASTM C595 & ASTM C1157 Type IP(MS) or IL(MS) Blended

Cement.

b. Gaskets: Comply with ASTM C923.

2. Joints:

a. Comply with ASTM C913.

b. Maximum Leakage: 0.025 gal. per hour per foot of joint at 3 feet of head.

C. Shaft and Eccentric Cone Top Sections:

1. Sections: Reinforced precast concrete.

2. Joints:

a. Lipped male/female.

3. Hold Down Bolt Inserts:

a. 4 inserts to accommodate 3/4-inch frame hold down bolts.

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b. Ultimate tension load capacity: 12,500 pounds.

c. Locations coordinated with frame.

D. Shape: Cylindrical.

E. Clear Inside Dimensions:

1. As indicated on Standard Detail Drawings and Work Order.

F. Design Depth:

1. As indicated on Standard Detail Drawings and Work Order.

G. Clear Cover Opening:

1. As indicated on Standard Detail Drawings and Work Order.

H. Pipe Entry: Furnish openings as indicated on Standard Detail Drawings.

I. Manhole Steps: As indicated on Standard Detail Drawings.

2.2 FRAMES AND COVERS

A. Manufacturers:

1. EJ.

2. Neenah.

3. Or approved equal.

B. Description:

1. Material:

a. Cast iron.

b. Comply with ASTM A48, Class 35B.

2. Cover:

a. Bearing Surface: Machined flat.

3. Cover Design: As indicated on Standard Detail Drawings.

4. Live-Load Rating: AASHTO Highway Loading Class H-20.

5. Furnish sealing gasket installed in grove machined into cover.

6. Cover: Molded with SANITARY name.

7. Frame Hold-down Bolts: ¾” diameter Type 316 stainless steel bolts and washers.

8. Nominal Size: As indicated on Standard Detail Drawings.

2.3 RISER RINGS

A. Manufacturers:

1. Pro-Ring as manufactured by Cretex Specialty Products.

2. Lad-Tech.

3. Or approved equal.

B. Description:

1. Material:

a. Expanded polypropylene Grade Rings comply with ASTM D3575.

b. Finished Density: 7.5 pcf.

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2. Grade Adjustment rings: upper and lower keyway (tongue and groove) for vertical alignment and/or adhesive trench.

3. Finish or Flat rings: keyway (groove) on the underside for vertical alignment and/or adhesive trench.

4. Finish rings: keyway on the upper surface.

5. Angle rings: upper and lower keyway (tongue and groove) for vertical alignment and/or adhesive trench.

6. Adhesive/Sealant:

a. As recommended by the manufacturer.

b. Comply with ASTM C-920, Type S, Grade NS, Class 25, Uses NT, T, M, G, A, and O.

c. Shall be M-1 Structural Adhesive/Sealant, or equal.

7. Repair Mortar:

a. One component, quick set, high strength, non-shrink; polymer modified cementitious patching mortar.

b. Comply with ASTM C-109 for compressive strength.

c. Comply with ASTM C348 and C-78 for Flexural strength.

d. Comply with ASTM C-882 for Slant Shear Bond Strength.

e. Shall be Octocrete by IPA Systems, or equal.

2.4 MANHOLE ENCAPSULATION SYSTEM

A. Heat-Shrinkable Sleeves:

1. Material: Irradiated and cross-linked polyethylene impermeable backing, coated with protective heat-activated adhesive.

2. Bonding: Bond to primed concrete surfaces.

3. Closure: Separate closure seal to secure sleeve in place during installation and seal overlap area.

B. Functional Performance of Heat-Shrinkable Sleeves:

1. Peel Strength (ASTM D1000): 8.6 pli.

2. Lap Shear (ASTM D1002): 1.5 psi.

3. Water Absorption (ASTM D570): 0.05%, maximum.

4. Low Temperature Flexibility (ASTM D2671): -40°F.

C. Physical Properties of Heat-Shrinkable Sleeves:

1. Supplied Thickness: 101 mils.

2. Fully Recovered Thickness: 125 mils.

3. Shrink Factor: 40%, minimum.

D. Sleeve Backing:

1. Tensile Strength (ASTM D638): 2,900 psi.

2. Elongation (ASTM D638): 600%.

3. Hardness (ASTM D2240) Shore D: 46.

4. Abrasion Resistance (ASTM D1044): 35 mg.

E. Primer: In accordance with Manufacturer recommendation.

Herbert, Rowland & Grubic, Inc. 33 05 61 - 6 000598.0465

2.5 MATERIALS

A. Cover and Bedding:

1. Bedding: PennDOT 2A aggregate, as specified in Section 31 05 16 - Aggregates for

Earthwork.

2. Cover within roadway: PennDOT 2A aggregate, as specified in Section 31 05 16 -

Aggregates for Earthwork.

3. Cover outside roadway: Suitable Fill, as specified in Section 31 05 13 - Soils for

Earthwork.

2.6 ACCESSORIES

A. Steps:

1. Rungs: steel reinforced formed PP.

2. Width:

a. As indicated on Standard Detail Drawings.

3. Spacing:

a. As indicated on Standard Detail Drawings.

B. Pipe Openings:

1. Resilient Gasket Type Pipe Opening Seals:

a. Manufacturers:

1) A-LOK Products Corporation; A-LOK X-Cel Connectors.

2) Hamilton Kent; Tylox Dual Seal II Series.

3) Or approved. equal.

b. Cast integrally with manhole component conforming to requirements specified in ASTM C923.

2. Expandable Sleeve Type: ASTM C923, consisting of a power sleeve, gasket and two (2) take up clamps. Power sleeve is mechanically expanded to compress gasket against receptacle hole in manhole wall. Install at precast plant:

a. Power Sleeve: Type 304 stainless steel, 85,000 psi yield strength.

b. Gasket: Compound Polyisoprene suitable for use with raw sewage.

c. Take Up Clamps: Type 304 stainless steel with stainless steel screw.

C. Joint Sealant: Comply with ASTM C990 and Fed. Spec. SS-S-210A, Type 1.

D. Fasteners: Stainless steel; ASTM F593.

E. Expandable Pipe Plug:

1. Manufacturers:

a. Taylor Made Plastics, Inc.

b. Or approved equal.

F. Manhole Adapter (for cored holes):

1. A watertight flexible pipe-to-manhole connector. The connector shall be PSX:

Direct Drive as manufactured by Press-Seal Corporation, or equal.

2. The connector shall provide a flexible watertight seal of the pipe to the manhole.

The connector shall consist of a rubber gasket, an internal expansion sleeve, and one or more external compression take-up clamps. Materials for the connection

Herbert, Rowland & Grubic, Inc. 33 05 61 - 7 000598.0465 shall be natural or synthetic rubber and Series 300 non-magnetic stainless steel.

Connector shall meet the requirements of ASTM C 923.

G. Manhole Adapter (for cast-in-place): Provide manhole adapters for use on pipe entering manhole base where manhole base is of cast-in-place construction:

1. Gasket type waterstop composed of SBR with stainless steel hardware as manufactured A-Lok, Fernco, or equal.

H. Waterstop Gasket:

1. Ring: Ring style waterstop gasket composed of elastomeric polyvinyl chloride

(PVC) such as manufactured by Fernco Joint Sealer Co., Press-Seal Gasket Corporation, or equal.

2. Strip: Flexible strip style bentonite style waterstop.

I. Waterstop Paste: Hydrophyilic paste type waterstop.

J. Grouting – Refer to Section 03 60 00.

2.7 PRECAST REINFORCED CONCRETE STORM SEWER MANHOLE COMPONENTS

A. Provide reinforced concrete precast storm sewer manholes. Storm sewer manhole construction shall conform to the requirements of the latest edition of the PennDOT Publication 408 and PennDOT Publication 72 RC-39M.

B. Storm sewer manhole frames and covers shall be constructed of ductile or malleable cast iron conforming to PennDOT Publication 408 and PennDOT Publication 72 RC-39M:

1. The use of gray, malleable, or ductile iron, or steel grade adjustment rings shall not be permitted for new construction.

C. Provide manhole steps meeting requirements of Paragraph 2.1.I.

D. All lifting holes shall be sealed after construction.

E. Provide waterstop gasket meeting requirements of Paragraph 2.6.H and grout all pipe entries flush to interior walls for watertight connection.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Section 01 73 00 - Execution Requirements: Requirements for installation examination.

B. Verify that items provided by other Sections of Work are properly sized and located.

C. Verify that built-in items are in proper location and are ready for roughing into Work.

D. Verify that excavation base is ready to receive Work and excavations and that dimensions and elevations are as indicated on the Work Order.

Herbert, Rowland & Grubic, Inc. 33 05 61 - 8 000598.0465

E. Inspect precast reinforced concrete structure components in accordance with requirements of ASTM C 478 and PennDOT Publication 408 and PennDOT Publication 72 regarding repairable defects and defects subject to rejection by the Engineer.

F. All material found during the progress of the work, either before or after installation, to have cracks, flaws or other defects will be rejected by the Engineer. All defective materials furnished by the Contractor shall be promptly removed from the site.

3.2 PREPARATION

A. Section 01 73 00 - Execution Requirements: Requirements for installation preparation.

B. Mark each precast structure by indentation or waterproof paint showing date of manufacture, manufacturer, and identifying symbols and numbers as indicated on Standard Detail Drawings to indicate its intended use.

C. Coordinate placement of inlet and outlet pipe or duct sleeves as required by other Sections.

D. Do not install manholes and structures where Site conditions induce loads exceeding structural capacity of manholes or structures.

E. Inspect precast concrete manholes and structures immediately prior to placement in excavation to verify that they are internally clean and free from damage; remove and replace damaged units.

F. Keep pipe and precast structure interiors cleared of debris as construction progresses.

3.3 INSTALLATION

A. Conduct operations not to interfere with, interrupt, damage, destroy, or endanger integrity of surface structures or utilities in immediate or adjacent areas.

B. Correct over-excavation with coarse aggregate.

C. Remove large stones or other hard matter impeding consistent backfilling or compaction.

D. Protect manhole from damage or displacement while backfilling operation is in progress.

E. Excavating:

1. As specified in Section 31 23 16 – Excavation and in indicated locations and depths.

2. Provide clearance around sidewalls of manhole or structure for construction operations, granular backfill.

3. If ground water is encountered, prevent accumulation of water in excavations;

place manhole or structure in dry trench.

4. Where possibility exists of watertight manhole or structure becoming buoyant in flooded excavation, anchor manhole or structure to avoid flotation as approved by Engineer.

Herbert, Rowland & Grubic, Inc. 33 05 61 - 9 000598.0465

F. Base and Alignment:

1. Install manholes supported at proper grade and alignment on compacted crushed-stone bedding.

2. Grout base of shaft sections to achieve slope to exit piping, trowel smooth, and contour to form continuous drainage channel.

3. Form and place manhole or structure cylinders plumb and level, to correct dimensions and elevations.

G. Attachments:

1. Set cover frames and covers level to correct elevations without tipping.

H. Backfilling: As specified in 31 23 23 - Fill.

I. Manhole Installation:

1. Precast Concrete Bases: Install manhole and chamber bases on an 8-inch-deep compacted layer of 2A coarse aggregate:

a. When using prefabricated pipe opening seals (i.e., A-LOK, Tylox, etc.) for connecting pipes into manholes, and such seals create an annular space on interior and exterior of manhole wall pipe openings after pipe connection is made, fill such annular spaces with preformed plastic sealing compound:

1) Tightly caulk sealing compound into annular spaces in a manner to completely fill the spaces and render the installation watertight.

2) Following sealing compound installation, trowel compound surface smooth and flush with interior face of manhole.

b. For other pipe connections into manholes: Install manhole adapter and grout all pipe entries flush to interior walls for watertight connection.

Refer to Section 03 60 00.

2. Length of Pipe Connections into Manholes:

a. Use pipes no longer than 5-feet in length when connecting into manholes through resilient gasket type pipe opening seals.

b. For all other pipe connections into manholes, use pipes of such length that a pipe joint is provided at the outside edge of manhole base or wall as applicable. Also use pipes no longer than 6 feet in length for first pipe joined thereto.

3. Concrete Channel Fill: Field pour concrete channel fill for each manhole base:

a. Form inverts directly in concrete channel fill.

b. Accurately shape invert to a semi-circular bottom conforming to inside of connecting pipes, and steel trowel finish to a smooth dense surface.

c. Make changes in size and grade gradually.

d. Make changes in direction of entering sewer and branches to a true curve of as large a radius as manhole size will permit.

e. Make slopes gradual outside the invert channels.

4. Manhole Wall Erection: Provide precast reinforced concrete straight riser, tapered riser and top sections necessary to construct complete manholes. Fit the different manhole components together to permit watertight jointing and true vertical alignment of manhole steps:

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a. Install sealing compound in accordance with manufacturer’s recommendations and join sections also in accordance with written instructions of manhole component manufacturer:

1) Prime joint surfaces if required by preformed sealing compound manufacturer.

2) If sealing compound is installed in advance of section joining leave exposed half of two-piece protective wrapper in place until just prior to section joining.

3) Use preformed sealing compound as the sole element utilized in sealing section joints from internal and external hydrostatic pressure.

4) To improve workability of "Preformed Plastic Sealing Compound" during cold weather, store such at temperature above 70°F or artificially warm compound in a manner satisfactory to the Engineer.

5) During warm weather stiffen "Preformed Plastic Sealing Compound" by placing under cold water or by other means as recommended by the compound manufacturer.

6) Following manhole section installation, trowel sealing compound surface smooth and flush with interior face of manhole.

7) Make pipe connections into manhole walls as specified previously for pipes connecting into manhole bases.

8) Remove all interior excessive plastic sealing compound after all manhole sections have been set.

5. Lifting Recess Sealing: Seal with properly designed tapered rubber plugs. Drive plugs into recesses in such manner to render them completely water and airtight.

Sealing of lifting recesses with grout is not permitted.

6. Frame and Cover:

a. Where required, make final adjustment of frame and cover to elevation using grade rings. Grade elevation adjustments shall not be permitted to exceed twelve (12) inches:

1) Frame and covers installed within paved areas shall be set at 1/8” below final pavement elevation.

2) Frame and covers installed in all other areas shall be set within

1/8” of final grade elevations, with exception of manholes with rim elevations identified above final grade elevations.

b. Joints between grade rings for leveling units shall be made with a manufacturer recommend adhesive/sealant.

c. The joint between the bottom of the frame and the top of grade ring leveling units, or the top manhole section as applicable, shall be made with manufacturer recommend adhesive/sealant.

d. Frames shall be bolted to the manhole. Studs, nuts, and washers shall be of stainless steel. Bolts shall have a sufficient number of proper sized threads for proper connection.

7. Connections to Existing Manholes:

a. Vacuum test existing manhole prior to making connection.

b. Cut required opening by core drilling; prevent cracking and spalling. Make openings of sufficient size to accommodate pipe and expandable sleeve

Herbert, Rowland & Grubic, Inc. 33 05 61 - 11 000598.0465 manhole adapter. Install expandable sleeve manhole adapter and tighten against structure and pipe. Grout pipe entry flush to interior wall and make connection watertight. Form a new flow channel in the existing manhole base to properly conduct all flows through the existing manhole.

Do not permit ground water, surface water or debris to enter the existing facilities. Maintain all existing flow during construction.

c. Perform vacuum test on existing manhole after making connection to assure water tightness of manhole.

8. Connections to Existing Sewers: Where new manholes are constructed on existing sewers, the Contractor shall have the option to use cast-in-place manhole bases or precast bases, both as specified previously:

a. Replace with new, broken or damaged pipe resulting from this work. New pipe material shall match existing. Use solid sleeve coupling.

b. Connect new pipe to new manhole bases or new in-line structures as specified previously.

c. If precast manhole bases are used, replace existing sewer pipe with new to first joint outside the manhole.

d. Maintain flow in existing sewer both during construction operations and until concrete is cured both in the case of cast-in-place work and formed inverts.

e. Cut with a saw piping to be removed. Chipping or breaking pipe with a hammer not permitted.

3.4 FIELD QUALITY CONTROL

A. Section 01 40 00 - Quality Requirements: Requirements for inspecting and testing.

B. General: Test each manhole constructed as specified herein:

1. Conduct tests in presence of and to complete satisfaction of the Engineer.

2. Should a manhole not satisfactorily pass testing, discontinue manhole construction in the Project until such manhole does test satisfactorily.

3. Provide tools, materials (including water), equipment and instruments necessary to conduct manhole testing specified herein.

4. Prior to testing manholes, thoroughly clean such and seal openings, both to complete satisfaction of the Engineer. Seal openings using properly sized plugs.

5. Perform manhole testing with frames installed. The joint between the manhole and the manhole frame shall be included in the test.

6. The tests of the manholes for acceptance shall be conducted after the backfilling has been completed.

C. Testing:

1. Concrete Manhole Sections: As specified in Section 33 05 05.36 - Vacuum Testing.

D. The Engineer shall conduct visual inspection of the sewer manholes.

E. Equipment Acceptance: Adjust, repair, modify, or replace components failing to perform as specified and rerun tests.

F. Repair and Retest: Determine source or sources of leaks in manholes failing acceptable

Herbert, Rowland & Grubic, Inc. 33 05 61 - 12 000598.0465 limits:

1. Repair or replace defective materials and workmanship, as is the case, and conduct such additional Manhole Acceptance Tests and such subsequent repairs and retesting as required until manholes meet test requirements.

2. Materials and methods used to make manhole repairs must meet with Engineer's approval prior to use.

3. Make repairs, replacements and retests at no additional expense to Owner.

END OF SECTION