33 05 61- CONCRETE MANHOLES

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SECTION 33 05 61 – CONCRETE MANHOLES

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes:

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

2. Bedding and cover materials.

B. Related Requirements:

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

2. Section 31 23 16.13 - Trenching: Excavating for manholes, structures, and foundation slabs.

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

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.

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

Studs.

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

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C. Shop Drawings:

1. Indicate structure locations and elevations.

2. Indicate sizes and elevations of piping penetrations.

D. Manufacturer's Certificate: Certify that products meet or exceed specified requirements.

1. Pennsylvania Steel Products Procurement Act compliance certification.

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

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

G. Qualifications Statement:

1. Submit qualifications for manufacturer.

1.6 CLOSEOUT SUBMITTALS

A. Section 01 77 00 - Execution and Closeout Requirements: Requirements for submittals.

B. Project Record Documents: Record actual locations of manholes and connections, and record invert elevations.

1.7 QUALITY ASSURANCE

A. 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.

1.8 QUALIFICATIONS

A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum three years' documented experience.

1.9 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.

D. Storage:

1. Store materials according to manufacturer instructions.

2. Store precast concrete manholes to prevent damage to Owner's property or other public or private property.

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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.

1.10 AMBIENT CONDITIONS

A. Section 01 50 00 - Temporary Facilities and Controls: Requirements for ambient condition control facilities for product storage and installation.

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

1.11 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 equal.

4. Substitutions: As approved by Owner.

B. Manhole Sections:

1. Materials:

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

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.

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

c. Locations coordinated with frame.

D. Shape: Cylindrical.

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E. Clear Inside Dimensions:

1. As indicated on Drawings.

F. Design Depth:

1. As indicated on Drawings.

G. Clear Cover Opening:

1. As indicated on Drawings.

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

I. Manhole Steps: As indicated on Drawings.

2.2 FRAMES AND COVERS

A. Manufacturers:

1. EJ.

2. Neenah.

3. Or Equal.

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. Cover:

a. Bearing Surface: Machined flat.

3. Cover Design: As indicated on 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 SEWER name.

7. Pickholes: Epic.

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

9. Nominal Size: As indicated on Drawings.

2.3 RISER RINGS

A. Manufacturers:

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

2. Lad-Tech.

3. Or-Equal.

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

B. Description:

1. Material:

a. Expanded polypropylene Grade Rings, comply with ASTM D3575.

b. Finished Density: 7.5 pcf.

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

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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.

2.5 MATERIALS

A. Cover and Bedding:

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1. Bedding: AASHTO No. 57, 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.

2.6 ACCESSORIES

A. 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 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.

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

C. Fasteners: Stainless steel; ASTM F593.

D. Expandable Pipe Plug:

1. Manufacturers:

a. Taylor Made Plastics, Inc.

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

E. 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.

F. Manhole Odor Control Insert:

1. Manufacturers: Parsons Environmental, Wolverine, Or Equal.

2. HDPE insert dish that supports a canister containing 20 lbs. of activated carbon.

2.7 SOURCE QUALITY CONTROL

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

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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.

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 Drawings.

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 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.

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.

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E. Excavating:

1. As specified in Section 31 23 16.13 - Trenching and in indicated locations and depths.

2. Provide clearance around sidewalls of manhole 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 becoming buoyant in flooded excavation, anchor manhole or structure to avoid flotation as approved by Engineer.

F. Base and Alignment:

1. Install manholes supported at proper grade and alignment on compacted crushed-stone bedding support system as indicated on Drawings.

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

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 Section 31 23 16.13 - Trenching.

I. Precast Concrete Manholes:

1. Lift precast components at lifting points designated by manufacturer.

2. When lowering manholes into excavations and joining pipe to units, take precautions to ensure that interior of pipeline and structure remains clean.

3. Assembly:

a. Assemble multisection 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. Remove foreign materials from joint surfaces and verify that sealing materials are placed properly.

5. Maintain alignment between sections by using guide devices affixed to lower section.

6. Joint sealing materials may be installed on Site or at manufacturer's plant.

7. Verify that installed manholes meet required alignment and grade.

8. Seal lifting recesses with rubber plugs or polymer grout repair mortar.

9. Cut pipe flush with interior of structure.

10. Shape inverts through manhole as indicated on Drawings.

J. Frame and Cover:

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1. 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:

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 a manufacturer recommend adhesive/sealant.

3. 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.

4. 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.

K. Connections to Existing Manholes:

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

3.4 FIELD QUALITY CONTROL

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

B. Testing:

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

2. Rectangular Concrete Manhole Sections: Visual leakage test performed by the

Engineer.

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

END OF SECTION