33 05 61 – Concrete Manholes

1.0 General

1.1 Summary

A. Section Includes:

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

2. Doghouse manhole connections to existing sewer lines.

3. Bedding and cover materials.

B. Related Requirements:

1. Section 03 11 00 - Concrete Forming: 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 manholes.

4. Section 31 23 33 – Trenching and Backfilling for Utilities: Excavation

Backfill for manhole and structure installation.

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

6. Section 33 31 11 - Public Sanitary Sewerage Gravity Piping: Piping connections to manholes.

1.2 Definitions

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

1.3 Reference Standards

A. American Association of State Highway Transportation Officials:

1. AASHTO M91 - Standard Specification for Sewer and Manhole Brick (Made from Clay or Shale).

2. AASHTO M306 - Standard Specification for Drainage, Sewer, Utility, and

Related Castings.

B. ASTM International:

1. ASTM A48/A48M - Standard Specification for Gray Iron Castings.

2. ASTM C478 - Standard Specification for Circular Precast Reinforced

Concrete Manhole Sections.

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

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

Underground Precast Concrete Utility Structures.

5. ASTM C913 - Standard Specification for Precast Concrete Water and

Wastewater Structures.

6. ASTM C923 - Standard Specification for Resilient Connectors between

Reinforced Concrete Manhole Structures, Pipes, and Laterals.

7. ASTM C990 - Standard Specification for Joints for Concrete Pipe, Manholes, and Precast Box Sections Using Preformed Flexible Joint Sealants.

8. ASTM F593 - Standard Specification for Stainless Steel Bolts, Hex Cap

Screws, and Studs.

9. ASTM F1554 - Standard Specification for Anchor Bolts, Steel, 36, 55, and

105-ksi Yield Strength.

C. PennDOT Publication 408, latest edition.

D. PennDOT Publication 72 – Standards for Roadway Construction (RC’s), latest edition.

1.4 Coordination

A. Section 01 31 13 – Project Coordination: Requirements for coordination.

1.5 Submittals

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

B. Product Data: The Contractor shall submit manufacturer detail drawings, modified to suit design conditions if required, and Contractor prepared drawings as applicable. Detail drawings shall include information for manhole covers, component construction, features, grade adjustments, configuration, and dimensions.

C. Contractor shall conduct a manned entry field investigation of each existing manhole that is to be replaced to confirm existing pipe sizes, inverts, and angle of connections prior to submitting shop drawings.

D. Shop Drawings:

1. Indicate structure locations and elevations.

2. Indicate sizes and elevations of piping penetrations.

E. Manufacturer's Certificate: The Contractor is responsible to ensure that the manufacturer certifies that products meet or exceed specified requirements.

1. PennDOT CS-430 form for all Precast Concrete Structures within the

PennDOT right-of-way.

2. PennDOT Pub 72.

3. Pennsylvania Steel Products Procurement Act compliance certification.

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

5. Manhole Frame and Cover:

a. Certificate of material compliance with ASTM A48, Class 35B tensile strength. Furnish certification that tensile test bars were from same pour as castings.

b. Manufacturer certification AASHTO HS-20 highway loading requirements.

F. Manufacturer Instructions: Submit detailed instructions on installation requirements, including storage and handling procedures.

G. Source Quality-Control Submittals: Indicate results of shop tests and inspections.

1. Manufacturer sworn certification that sanitary sewer manholes were constructed using Type II (or equivalent) Portland cement.

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

3. 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.

H. Field Quality-Control Submittals: Indicate results of Contractor-furnished tests and inspections.

I. Qualifications Statement:

1. The Contractor shall submit qualifications for manufacturer.

J. For all Precast Concrete Structures within the PennDOT right-of-way submit completed PennDOT CS-430 form. This form shall be completed by the

Contractor, not the material supplier.

1.6 Closeout Submittals

A. Section 01 77 00 – Closeout Procedures: Requirements for submittals.

B. Project Record Documents: The Contractor shall record actual locations of manholes and connections, and record invert elevations, and shall furnish all such information to the Engineer at the conclusion of the Project.

1.7 Quality Assurance

A. Perform Work according to PennDOT and City of Harrisburg Standards.

B. Structural Design Loading: Unless otherwise noted, the Contractor is responsible to ensure that utilities, structures and underground conveyance systems are 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.

1.8 Qualifications

A. Manufacturer: Company specializing in manufacturing products specified in this

Section with minimum three years' documented experience:

1. Manufacturer shall be listed in PennDOT Bulletin 15.

1.9 Delivery, Storage, And Handling

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

B. Inspection: The Contractor shall accept materials on Site in manufacturer's original packaging and inspect for damage.

C. Handling: The Contractor shall comply with precast concrete manufacturer instructions and ASTM C913 for unloading and moving precast manholes and drainage structures.

D. Storage:

1. The Contractor shall store materials according to manufacturer instructions.

2. The Contractor shall store precast concrete manholes to prevent damage to

Owner's property or other public or private property.

3. The Contractor shall repair property damaged from materials storage.

E. Protection:

1. The Contractor shall protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas.

2. The Contractor shall provide additional protection according to manufacturer instructions.

1.10 Existing Conditions

A. Field Measurements:

1. The Contractor shall verify field measurements prior to fabrication.

2. The Contractor shall indicate field measurements on Shop Drawings.

2.0 Products

2.1 Concrete Manholes

A. Manufacturers:

1. Monarch Precast Concrete.

2. Terre-Hill Precast.

3. Or equal, approved by the Engineer.

4. Substitutions: As specified in Section 01 61 00 – Product Requirements.

B. Manhole Sections:

1. Materials:

a. Reinforced Precast Concrete: Comply with ASTM C478 with 4,500 psi

Type II, 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. Anti-microbial Admixture: Xypex Biosan C-500, or equal.

c. 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 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.

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

c. Locations coordinated with frame.

D. Shape: Cylindrical or rectangular:

1. As indicated on Drawings.

E. Clear Inside Dimensions:

F. Design Depth:

G. Clear Cover Opening:

H. Pipe Entry:

1. Furnish openings as indicated on Drawings.

I. Structure Joint Gaskets:

1. Comply with ASTM C361.

2. Material: Rubber.

2.2 Frames And Covers

A. Manufacturers:

1. East Jordan Iron Works, Frame – 1045-Z; Cover – 1040-A.

2. Neenah Foundry Company.

3. Or Equal, approved by the Engineer.

4. Substitutions: As specified in Section 01 61 00 – Product Requirements.

B. Description:

1. Material:

a. Cast iron.

b. Comply with ASTM A48/A48M, Class 35B.

2. Lid:

a. Bearing Surface: Machined flat.

b. Configuration: Removable with two concealed pick holes.

3. Cover Design: Watertight and molded with the word “SEWER” cast into the cover. Lettering shall be a minimum of 2-inches high.

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

5. Frame shall have four (4) 1-inch diameter holes in frame flange equally spaced.

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

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

8. Provide machined dovetail groove centered in lip seat of cover for ¼-inch diameter continuous loop polyisoprene or neoprene rubber gasket (40 durometer).

9. Cover casting shall be black asphaltic coated.

10. Nominal Size: 24-inch minimum clear access opening.

2.3 Grade Rings

A. Grade Rings:

1. General: Grade adjustment for a manhole shall not exceed twelve (12) inches, and shall be used sparingly.

a. In vehicle trafficked areas (e.g., roadways, parking lots, etc.), a rubber grade ring shall be used for grade adjustment. In such areas and where multiple grade rings are required, only the top (final) grade ring is to be rubber.

b. Concrete grade rings are to be used outside of vehicle trafficked areas.

And in instances where multiple rings are required but the structure is within a vehicle trafficked area, concrete grade rings may be used as long as the top (final) grade adjustment ring is made of rubber.

2. Concrete Grade Rings:

a. Shall be single piece, no thinner than two (2) inches thick; and no thicker than five (5) inches.

b. Shall be made of Class AA Cement Concrete Modified (see PennDOT Pub

408) and shall have a minimum 28-day compressive strength of 4,000 pounds per square inch.

3. Rubber Grade Rings:

a. Rubber grade rings (rubber adjustment riser) for leveling units shall comply with the following:

PHYSICAL PROPERTIES TEST RESULTS TEST METHOD

Density 1.098 g/cm3 ASTM C 642 - 90

Durometer Hardness

- Molded surface

- Interior surface

75A10 points

73A10 points

Based on ASTM D

Tensile Strength

Compression

Deformation

- Initial deformation

- Final deformation

1.6 MPa (232 psi)

(not less than 1 MPa) under 1 MPa

(145 psi)

64%

64%

ASTM D 412 – 87

Based on ASTM D

Compression Set 0.4% (no more than

4%) under 1 MPa

(145 psi)

Based on ASTM D

Freeze and Thaw When Exposed to Deicing Chemicals no loss after 50 cycles ASTM C 672 - 91

Coefficient of Thermal Expansion 1.08 x 10-4 mm/mm/C

(6 x 10-5 in/in/F)

ASTM C 531 - 85

PHYSICAL PROPERTIES TEST RESULTS TEST METHOD

Weathering (70 hours at 70 C)

- Hardness retained

- Compressive strength re-tained

- Tensile strength retained

- Elongation retained

100%5%

100%5%

100%5%

100%5%

ASTM D 573 - 88

b. Rubber grade rings shall only be used in vehicle trafficked areas.

c. Tapered rubber grade rings shall be used to accommodate sloped paved surfaces.

B. Coatings:

1. Exterior: Apply two (2) coats of coal tar epoxy to outer surface of entire manhole.

1)

C. Accessories:

1. Joint Sealant: Comply with ASTM C990.

2. Bolts: Type 304 stainless steel; ASTM F593.

2.4 MATERIALS

A. Cover and Bedding:

1. As specified in Section 31 23 33 – Trenching and Backfilling for Utilities.

2.5 ACCESSORIES

A. Steps:

1. Manufacturers:

a. MA Industries, Inc.; Type PS-2-B.

b. American Step Company, Inc.

c. Or equal, as approved by the Engineer.

2. Rungs: Steel reinforced formed PP.

3. Width:

a. As indicated on Drawings.

4. Spacing:

a. As indicated on Drawings.

B. Foundation Slab:

1. Cast-in-place concrete as specified in Section 03 30 00 – Cast-in-Place

Concrete.

2. Top Surface: Level.

C. Pipe Openings:

1. 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.

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

E. Fasteners: Type 304 stainless steel; ASTM F593.

F. Expandable Pipe Plug:

1. Manufacturers:

a. Taylor Made Plastics, Inc.

b. Substitutions: As specified in Section 01 61 00 - Product

Requirements.

G. 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 shall be natural or synthetic rubber and Series 300 non-magnetic stainless steel. Connector shall meet the requirements of ASTM C 923.

H. 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, as approved by the Engineer.

I. Sanded Manhole Adapter:

1. Shall be capable of passing a 10 PSI pressure test and withstands 20 in

Hg vacuum test.

2. PVC Manhole Adaptor with silica-impregnated surface.

3. Gasket shall maintain enough flexibility to adjust for pipe deflection long after installation.

J. 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, as approved by the Engineer.

2. Strip: Flexible strip style bentonite style waterstop.

K. Waterstop Paste: Hydrophyilic paste type waterstop.

L. Waterproofed Mortar:

1. Manufacturers:

a. Medusa Cement Company; Medusa Waterproofing Paste or

Powder.

b. Grace Construction Materials; Hydratite.

c. Chem-Master Corporation; Hydrolox.

d. Or equal, as approved by the Engineer.

2. Material composition meeting ASTM C270, Type M with waterproofing admixture included.

M. Epoxy Bonding Compound:

1. Manufacturers:

a. A. C. Horn EPOXTITE BINDER.

b. Sika Chemical SIKADUR-HI-MOD.

c. Euclid Chemical Company 452 EPOXY SYSTEM.

d. Or equal, as approved by the Engineer.

2. Provide a high-modulus, low viscosity, moisture insensitive epoxy adhesive having the following characteristics:

a. Mix Ratio: 100 percent solids, two components; mixed one part by volume component B to two parts by volume component A.

b. Ultimate Compressive Strength: 13,000 psi after cure at 73°F and 50 percent relative humidity determined in accordance with

ASTM D695.

N. Concrete: As specified in Section 03 30 00 – Cast-in-Place Concrete.

O. Grout: As specified in Section 03 60 00 – Grouting.

P. Rubber Seal Wraps:

1. Wraps and Band Widths: Comply with ASTM C877, Type III

2. Cone/Grade Ring Joint: Minimum 3-inch overlap.

3. Frame/Grade Ring Joint: 2-inch overlap.

4. Additional Bands: Overlap upper band by 2 inches.

2.5 Finishes

A. Bituminous Exterior Manhole Coating:

1. Coal tar epoxy designed for exterior buried concrete manhole application.

2.6 SOURCE QUALITY CONTROL

A. Section 01 40 00 – Quality Requirements: Requirements for testing, inspection, and analysis.

B. Provide shop inspection and testing of completed assembly.

C. Certificate of Compliance:

1. If manufacturer is approved by authorities having jurisdiction, submit certificate of compliance indicating Work performed at manufacturer's facility conforms to Contract Documents.

2. Specified shop tests are not required for Work performed by approved manufacturer.

3.0 Execution

3.1 Examination

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

B. The Contractor shall verify that items provided by other Sections of Work are properly sized and located.

C. The Contractor shall verify that built-in items are in proper location and are ready for roughing into Work.

D. The Contractor shall verify that excavation base is ready to receive Work and excavations and that dimensions and elevations are as indicated on Drawings.

3.2 Preparation

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

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

C. The Contractor shall coordinate placement of inlet and outlet pipes as required by other Sections.

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

E. The Contractor shall 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.

3.3 Installation

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

B. The Contractor shall correct over-excavation with coarse aggregate.

C. The Contractor shall remove large stones or other hard matter impeding consistent backfilling or compaction.

D. The Contractor shall protect manhole from damage or displacement while backfilling operation is in progress.

E. Excavating:

1. As specified in Section 31 23 33 – Trenching and Backfilling for Utilities and in indicated locations and depths.

2. The Contractor shall provide clearance around sidewalls of manhole or structure for construction operations granular backfill.

3. If ground water is encountered, the Contractor shall 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, the Contractor shall anchor manhole or structure to avoid flotation as approved by Engineer.

F. Base and Alignment:

1. The Contractor shall install manholes supported at proper grade and alignment on compacted crushed stone bedding support system as indicated on Drawings.

2. The Contractor shall grout base of shaft sections to achieve slope to exit piping, trowel smooth, and contour as indicated on Drawings.

3. The Contractor shall form and place manhole or structure cylinders plumb and level, to correct dimensions and elevations.

G. Length of Pipe Connections into Manholes: The Contractor shall use pipes no longer than five (5) feet in length when connecting into manholes through

Prefabricated Pipe Opening Seals:

1. 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.

H. Attachments:

1. The Contractor shall set cover frames and covers level to correct elevations without tipping.

I. Backfilling: As specified in Section 31 23 33 – Trenching and Backfilling for

Utilities.

J. Coating: The Contractor shall paint exterior with two coats of bituminous coating at manufactures recommended thickness.

K. Precast Concrete Manholes:

1. The Contractor shall lift precast components at lifting points designated by manufacturer.

2. When lowering manholes into excavations and joining pipe to units, the

Contractor shall take precautions to ensure that interior of pipeline and structure remains clean.

3. Assembly:

a. Assemble multi-section manholes and structures by lowering each section into excavation.

b. Install rubber gasket joints between precast sections according to manufacturer recommendations.

c. Lower, set level, and firmly position base section before placing additional sections.

4. The Contractor shall remove foreign materials from joint surfaces and verify that sealing materials are placed properly.

5. The Contractor shall maintain alignment between sections by using guide devices affixed to lower section.

6. The Contractor shall joint sealing materials may be installed on Site or at manufacturer's plant.

7. The Contractor shall verify that installed manholes meet required alignment and grade.

8. The Contractor shall cut pipe flush with interior of structure.

9. The Contractor shall shape inverts through manhole as indicated on

Drawings.

L. Cast-in-Place Concrete Manholes:

1. The Contractor shall ensure that the structure bears firmly and fully on compacted crushed stone bedding.

2. The Contractor shall erect and brace forms against movement as specified in Section

03 11 00 – Concrete Forming.

3. The Contractor shall install reinforcing steel as indicated on Drawings, as specified in Section

03 20 00 – Concrete Reinforcing, and in accordance with PennDOT requirements.

4. The Contractor shall place and cure concrete as specified in Section

03 30 00 – Cast-in-Place

Concrete.

M. Doghouse Manholes and Structures:

1. The Contractor shall stake out location and burial depth of existing sewer line in area of proposed manhole or structure.

2. The Contractor shall carefully excavate around existing sewer line to adequate depth for foundation slab installation.

3. The Contractor shall protect existing pipe from damage.

4. The Contractor shall cut out soft spots and replace with granular fill compacted to 95 percent maximum density.

5. The Contractor shall ensure that the structure bears firmly and fully on compacted crushed stone bedding.

6. The Contractor shall install precast concrete manhole or structure around existing pipe according to applicable Paragraphs in this Section.

7. The Contractor shall grout pipe entrances as specified in Section 0330 00 –

Cast-in-Place

Concrete.

8. The Contractor shall block upstream flow at existing manhole or structure with expandable plug.

9. The Contractor shall use hydraulic saw to cut existing pipe at manhole or structure entrance and exit and along pipe length at a point halfway up OD on each side of pipe.

10. The Contractor shall bottom half of pipe is to remain as manhole flow channel.

11. The Contractor shall saw cut to smooth finish with top half of pipe flush with interior of manhole or structure.

12. The Contractor shall grout base of manhole or structure to achieve slope to manhole or structure channel as specified in Section 03 30 00 – Cast-in-Place Concrete and trowel smooth.

N. Frame and Cover:

1. Where required, the Contractor shall make final adjustment of frame and cover to elevation using grade rings. Grade elevation adjustments shall not be permitted to exceed the vertical distance noted on the Drawings.

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

b. 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.

2. Joints between grade rings for leveling units shall be made with joint sealant and completely fill joints.

3. 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.

3.4 FIELD QUALITY CONTROL

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

B. Testing:

1. Cast-in-Place Concrete: As specified in Section 03 30 00 – Cast-in-Place

Concrete.

2. Concrete Manhole Sections: As specified in Section 33 05 05.36 –

Vacuum Testing.

C. Equipment Acceptance: The Contractor shall adjust, repair, modify, or replace components failing to perform as specified and rerun tests, at no additional cost to the Owner.

END OF SECTION 33 05 61

J. For all Precast Concrete Structures within the PennDOT right-of-way submit completed PennDOT CS-430 form. This form shall be completed by the Contractor, not the material supplier.

C. Equipment Acceptance: The Contractor shall adjust, repair, modify, or replace components failing to perform as specified and rerun tests, at no additional cost to the Owner.