33 31 23 - Sanitary Sewerage Pressure Piping.pdf

33 31 23 - SANITARY SEWERAGE PRESSURE PIPING

Herbert, Rowland & Grubic, Inc. 33 31 23 - 1 000598.0465

SECTION 33 31 23 - SANITARY SEWERAGE PRESSURE PIPING

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes:

1. Force mains.

1.2 REFERENCE STANDARDS

A. American Association of State Highway and Transportation Officials:

1. AASHTO T180 - Standard Method of Test for Moisture-Density Relations of Soils

Using a 4.54-kg (10-lb) Rammer and a 457-mm (18-in.) Drop.

B. American Water Works Association:

1. AWWA C104 - Cement-Mortar Lining for Ductile-Iron Pipe and Fittings.

2. AWWA C110 - Ductile-Iron and Gray-Iron Fittings.

3. AWWA C111 - Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings.

4. AWWA C151 - Ductile-Iron Pipe, Centrifugally Cast.

5. AWWA C900 - Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 4 In.

through 12 In. (100 mm through 300 mm), for Water Transmission and Distribution.

C. ASTM International:

1. ASTM D698 - Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3 (600 kN-m/m3).

2. ASTM D1557 - Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3 (2,700 kN-m/m3).

3. ASTM D1785 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120.

4. ASTM D2241 - Standard Specification for Poly(Vinyl Chloride) (PVC) Pressure-

Rated Pipe (SDR Series).

5. ASTM D2466 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe

Fittings, Schedule 40.

6. ASTM D2467 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe

Fittings, Schedule 80.

7. ASTM D6938 - Standard Test Method for In-Place Density and Water Content of

Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth).

1.3 SUBMITTALS

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

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B. Shop Drawings:

1. Indicate piping piece numbers and locations.

2. Indicate restrained joint locations.

1.4 CLOSEOUT SUBMITTALS

A. Project Record Documents: Record invert elevations and actual location of pipe runs and connections.

1.5 DELIVERY, STORAGE, AND HANDLING

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

B. Storage:

1. Store materials according to manufacturer instructions.

2. Do not place materials on private property without written permission of property owner.

3. Do not stack pipe higher than recommended by pipe manufacturer.

C. Protection:

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

2. Store gaskets for mechanical and push-on joints in cool and dry location, out of direct sunlight, and not in contact with petroleum products.

3. Provide additional protection according to manufacturer instructions.

1.6 GENERAL REQUIREMENT

A. Force mains installed and connected to an existing force main shall match the same design criteria and material of the existing pipe unless approved otherwise.

PART 2 - PRODUCTS

2.1 FORCE MAIN/LOW PRESSURE SEWER PIPING

A. Design Features:

1. All pressure sewer piping shall be sized to maintain low frictional losses in the system and a minimum scouring velocity of 2 ft/s at all points throughout the system.

2. Low Pressure Sewer Piping:

a. The pressure sewer system shall be laid out in a branch or tree configuration to avoid flow-splitting at branches which cannot accurately be predicted.

b. The determination of flow in the pressure sewer system shall be made on the basis of the maximum probable number of grinder pump units that would be expected to run simultaneously or some other accepted method of computing the peak sewage flow rate in the system.

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2.2 DUCTILE IRON PIPE AND FITTINGS:

A. Ductile iron pipe (DIP) of the sizes shown or specified shall conform to ANSI A21.51 (AWWA C151), Grade 60-42-10 for ductile iron pipe centrifugally cast in metal molds or sand-lined molds. All ductile iron pipe shall conform to ANSI A21.50 (AWWA C150) for thickness design and shall be supplied in 16-, 18-, or 20-foot nominal lengths unless approved otherwise. Ductile iron pipe shall be Pressure Class 350 for sizes less than 14” and Pressure Class 250 for size 14” and greater.

B. Fittings and specials shall be ductile iron, conforming to the requirements of ANSI A21.10 (AWWA C110) and shall have a minimum rated working pressure of 250 psi. All ductile iron pipe and specials shall be marked with the manufacturer's name or trademark, size, weight, thickness class, the date of manufacture, and the word "Ductile".

C. Pipe and Fittings Lining: Liner shall be in accordance with Part 2.03 of this Section.

D. Pipe and fittings shall be the class that equals or exceeds the pipe class as specified herein.

Requirements for various types of joints are described in the following paragraphs.

E. Flanged joints and fittings shall have a minimum pressure rating of 250 psi with 125 lb.

American Standard flanges. All flanges and fittings shall conform to the requirements of ANSI B16.1. Flanges shall be ductile iron and shall be of the threaded or screw on type.

The face of the flanges shall be machined after installation of the flange to the pipe. No raised surface shall be allowed on flanges. Flanged pipe shall conform to the requirements of ANSI Specification A21.15, (AWWA C115). Pipe lengths shall be fabricated to meet the requirements of the Drawings.

F. Gaskets shall be the "full face" type, 1/8-inch minimum thickness, SBR, Nitrile (NBR), EPDM, or neoprene and shall be suitable for use with sanitary sewage.

G. Bolts shall be of the size and length called for and in accordance with the "American Standard" and comply with the requirements of the ANSI/AWWA Standards. The bolts for flanged joints shall be a minimum ASTM A193-B8M, Class 1; 316 stainless steel and be in accordance with ANSI A21.10, (AWWA C110). The bolts shall have hexagonal heads and nuts, no washers shall be used. The bolts shall be tightened uniformly to distribute the bolt stress evenly and bring the pipe into alignment.

H. Mechanical joints and fittings shall conform to the requirements of ANSI A21.11, (AWWA C111) and have a minimum pressure rating of 250 psi. Joints shall be made employing a tapered rubber gasket forced into a tapered groove with a ductile iron follower ring. If required by installation conditions, pipe and fittings shall have cast-on lugs for adequately tying the pipe and fittings together. These shall be in conformance with standard practice and as outlined under the appropriate AWWA Specifications.

I. Bolts for mechanical joints shall be high strength corrosion resistant low-alloy steel tee-head bolts with hexagonal nuts. Bolts and nuts shall be painted with bituminous coating after installation.

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J. Mechanical Restrained Joints: Mechanical joint restraint consisting of fusion bonded epoxy coated follower gland which when actuated imparts multiple wedging action against the pipe, increasing its resistance as the pressure increases. ASTM A 536 ductile iron follower gland of dimensions such that it can be used with AWWA C153 mechanical joints. Restraining devices shall be of ductile iron, heat treated to a minimum hardness of 370 BHN. Twist-off nuts shall be used to insure proper actuating of the restraint device.

Restraint device shall have a 250-psi minimum working pressure with 2:1 minimum safety factor.

2.3 DUCTILE IRON SEWER PIPE AND FITTINGS LINING

A. Condition of Ductile Iron Pipe Prior to Surface Preparation:

1. All ductile pipe and fittings shall be delivered to the application facility without asphalt, cement lining, or any other lining on the interior surface. Because removal of old linings may not be possible, the intent of this Section is that the entire interior of the ductile iron pipe and fittings shall not have been lined with any substance prior to the application of the specified lining material and no coating shall have been applied to the first six inches of the exterior of the spigot ends.

B. Lining Material:

1. Interior surfaces of ductile iron pipes and fittings shall be lined with Protecto

401™ Ceramic Epoxy, Tnemec Permashield 431, or Lifelast Durashield 201 per manufacturer’s recommendations.

C. Application:

1. Surface Preparation: Abrasive Blast Cleaning per NAPF 500-03-04 shall be performed on all Ductile Iron pipe and fittings prior to lining.

2. Dry Film Thickness (DFT): Linings on all Ductile Iron pipe and fittings shall have a minimum DFT of 40 mils and shall be tested per NACE SSPC PA-2 Film Thickness Rating.

3. Testing for Pinholes: All linings shall be tested for pinholes using high voltage discontinuity testing per ASTM 5162.

4. It is the Contractor’s responsibility to make minor field repairs to any linings that are damaged during installation.

5. The Authority reserves the right to accept or reject any lined pipe or fittings that does not meet the requirements listed above.

D. Handling:

1. Lined pipe and fittings must be handled only from the outside of the pipe and fittings. No forks, chains, straps, hooks, etc. shall be placed inside the pipe and fittings for lifting, positioning, or laying. The pipe shall not be dropped or unloaded by rolling.

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2. Care should be taken not to let the pipe strike sharp objects while swinging or being off loaded. Ductile iron pipe should never be placed on grade by use of hydraulic pressure from an excavator bucket or by banging with heavy hammers.

2.4 HIGH DENSITY POLYETHYLENE (HDPE) PIPE

A. All pipe and fittings shall have product traceability. Pipe and fittings shall be heat indent printed with the manufacturer’s name, the nominal pipe size, the dimension ratio, the pipe grade, manufacturing standard reference, and the manufacturer’s production code, from which the date and place of manufacture can be determined.

B. Quality Control/Workmanship: All pipe and fittings shall be homogeneous throughout and free of visible cracks, holes, foreign inclusions, blisters, dents, or other defects. The piping and fittings shall be uniform in color, opacity, density, and other physical properties as commercially practical.

C. See Paragraph 3.03-D for Joining Methods.

D. HDPE Pipe (4” and smaller):

1. Polyethylene pipe shall be made from a HDPE material having a material designation code of PE 4710. The material shall meet the requirements of ASTM D3350 and shall have a minimum cell classification of 445574C.

2. HDPE pipe shall be SDR-11 and rated for use at a pressure class of 200 psi. The outside diameter of the pipe shall be based upon the pressure sizing system.

E. HDPE Pipe (above 4”):

1. HDPE pipe shall be made from HDPE material having a material designation code of PE 4710 or greater. The material shall meet the requirements of ASTM D3350 and shall have a minimum cell classification of 445574C.

2. HDPE pipe shall be rated for use at a pressure class of 200 (DR11) or 250 (DR9) psi, unless approved otherwise. The outside diameter of the pipe shall be based upon the pressure sizing system.

F. HDPE Fittings:

1. Butt and Socket Fusion Fittings:

a. Fittings shall be made of HDPE material with a minimum material designation code of PE 4710 (or greater if necessary for HDPE pipe exceeding 4” in diameter) and with a minimum Cell Classification as specified above.

b. Butt Fusion Fittings shall meet the requirements of ASTM D3261.

c. Socket fittings shall meet ASTM D2683.

d. Molded and fabricated fittings shall have a pressure rating equal to the pipe unless otherwise specified on the Contract Drawings.

e. Markings for molded fittings shall comply with the requirements of ASTM

D3261. Fabricated fittings shall be marked in accordance with ASTM F2206.

2. Electrofusion Fittings:

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a. Fittings shall be made of HDPE material with a material designation code of PE 4710 (or greater if necessary for HDPE pipe exceeding 4” in diameter) and with a minimum Cell Classification as specified above.

b. Electrofusion Fittings shall have a manufacturing standard of ASTM F1055.

c. Fittings shall have a pressure rating equal to the pipe.

d. All electrofusion fittings shall be suitable for use as pressure conduits and have nominal burst values of four times the Working Pressure Rating (WPR) of the fitting.

e. Markings shall be according to ASTM F1055.

3. HDPE Mechanical Joint (MJ) Adapters:

a. MJ assembly shall consist of HDPE anchor fitting, rubber gasket, extra-length high strength corrosion resistant low-alloy steel T-bolts, and heavy body ductile iron gland ring.

b. MJ adapters shall have a material designation code of PE 4710 (or greater if necessary for HDPE pipe exceeding 4” in diameter) and with a minimum Cell Classification as specified above.

c. MJ Adapters shall be made to ASTM D3261 or if machined, must meet the requirements of ASTM F2206.

d. MJ adapters shall have a pressure rating equal to the pipe.

e. Markings for molded or machined MJ Adapters shall be per ASTM D3261.

f. Bolts and nuts shall be painted with bituminous coating after installation.

4. HDPE Flanged Adapters:

a. Flanged adapters shall have a material designation code of PE 4710 (or greater if necessary for HDPE pipe exceeding 4” in diameter) and with a minimum Cell Classification as specified above.

b. Provide convoluted ductile iron bolt ring to meet ASME/ANSI B16.5, B16.47.

c. Flanged adapters shall be made to ASTM D3261 or if machined, must meet the requirements of ASTM F2206.

d. Flanged adapters shall have a pressure rating equal to the pipe.

e. Markings for molded or machined flange adapters shall be per ASTM

D3261.

f. The bolts for flanged joints shall be a minimum ASTM A193-B8M, Class 1;

316 stainless steel.

2.5 PVC C900 PIPING

A. PVC C900 pipe, DR 14, ASTM D2241, with an integral bell incorporating an internal joint restraint which utilizes a nylon spline locking system that results in an immediate, full-strength joint that is locked in both directions. Pipe restraint system shall contain no metal components. Pipe shall be made from quality PVC resin, compounded to provide physical and mechanical properties that equal or exceed cell class 12454 as defined in ASTM D1784.

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B. Hydrostatic Proof Testing: Each standard and random length of pipe is tested to two times the rated pressure of the pipe for a minimum of five (5) seconds. The integral bell shall be tested with the pipe.

C. Standard laying lengths shall be no longer than 20 feet for all sizes.

D. Pipe shall be suitable for use as pressure conduit. Provisions must be made for expansion and contraction at each joint with an elastomeric gasket. The bell shall consist of an integral wall section with a factory installed, solid cross section Rieber/other elastomeric gasket, which meets the requirements of ASTM F477. The bell section shall be designed to be at least as hydrostatically strong as the pipe barrel and meet the requirements of AWWA C900. The joint design shall meet requirements of ASTM D3139, under both pressure and 22 in. Hg vacuum.

E. Quick Burst Test: Randomly selected samples tested in accordance with ANSI/UL 1285 shall withstand, without failure, the pressures listed below when applied for 60-70 seconds. This test is performed on pipe sizes less than 30".

F. Flattening Test: Specimens of pipe, a minimum of 6 in. long, shall be flattened between parallel plates in a suitable press until the distance between the plates is 40 percent of the OD of the pipe. The rate of flattening shall be uniform and such that the compression is completed within 2 to 5 minutes. There shall be no evidence of splitting, cracking or breaking.

2.6 PIPELINE DETECTION AND MARKING

A. Pipeline Detection Tape:

1. Underground Warning or Pipeline Detection Tape for Sanitary Sewer.

a. Detection tape shall consist of a minimum 5.0 mil overall thickness with a solid aluminum core or backing capable of being detected.

b. Detection tape shall be minimum 6-inches wide, green in color, imprinted with the words “Caution-Sewer Line Below”, and capable of being detected with inductive methods.

B. Tracer Wire for HDPE Force Main Pipe and Low-Pressure Sewer Pipe:

1. Directional Drilling/ Boring / Pipe Bursting Applications: Tracer wire for directional drilling/boring shall be No. 12 AWG extra-high-strength copper-clad steel conductor (EHS-CCS), insulated with a 45 mil, high-density, high molecular weight polyethylene (HDPE) insulation, and rated for direct burial use at 30 volts.

EHS-CCS conductor must be a 21% conductivity for locate ability purposes, Break load shall be minimum of 1150 pounds. HDPE insulation shall be RoHS compliant and utilize virgin grade material. Insulation color shall be green sewer to meet the APWA color code standard for identification of buried utilities.

2. Open Cut/ Open Ditch Applications: Tracer wire for open cut/ open ditch shall be No. 12 AWG high-strength copper clad steel conductor (HS-CCS), insulated with a 30 mil, high-density, high molecular weight polyethylene (HDPE) insulation, and rated for direct burial use at 30 volts. HS-CCS conductor must be a 21%

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Insulation color shall be green sewer to meet the APWA color code standard for identification of buried utilities. Tracer wire shall be manufactured by Copperhead Industries, LLC or equal.

3. Anode: Provide Magnesium Drive in Anode with HDPE cap and 10’ of Red 14 AWG copper clad steel tracer wire (Factory Installed to Anode) with 30 mil high-density, high molecular weight polyethylene (HDPE) insulation, and rated for direct burial use at 30 volts, HDPE insulation shall be RoHS compliant and utilize virgin grade material for every 1,000 feet of tracer wire installed. Anode shall include non-hardening moisture displacement silicon corrosion resistant for splicing anode wire to main tracer wire as manufactured by Copperhead Industries, LLC or equal.

4. Tracer Wire Box:

a. Box shall be designed to be easily detected by magnetic and electronic locators even when box is covered by a minimum of four (4) inches of soil, sod and / or paving material. A magnet shall be securely attached at the top of the upper tube of the box for locating purposes. Material used to retain magnet in place shall remain effective at minus 15 degrees Fahrenheit.

b. Locking Mechanism: Lid of valve box shall be designed to employ a locking mechanism that will clamp it to the box collar in a closed position.

c. Box shall be of a cylindrical construction with removable round lid. Box shall have a support flange at the base of the lower tube bell at least one-half (1/2) inch wide.

d. Wire connection: Brass screw running through brass wire harness will be used as connection for locator transmitter hook-up. Brass wire harness shall be used to secure tracer wire leads to brass screw enabling locator equipment hoop-up. Petrolatum wax tape incorporated with magnetized tracer box to encapsulate tracer wire leads and brass wire harness.

e. Petrolatum wax tape must be formed around brass wire harness connection after tracer wire leads are connected to prevent oxidation of wire ends. In order to ensure proper long term locatibility and signal strength, the petrolatum wax tape must be utilized to prevent oxidation.

f. Lid: Box shall be designed so that when installed, the collar will be flush with the surface and contain the lid so that it will not be in contact with the adjoining backfill or pavement. The cavity which holds the lid shall be designed so that water drains into the inside of the box. The top surface of the box lid shall be flush with the top of the box. The top of the bolt or locking device when in the locked position shall be flush with or below the lid surface.

5. Use connectors and test stations approved by the tracer wire manufacturer for the installation method utilized.

6. Approved test station color shall be green sewer to meet the APWA color code standard for identification of buried utilities.

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2.7 THRUST RESTRAINT

A. Restraint shall be provided at open cut force main (non-fused) fittings, bends, tees, and changes in direction with the exception of HPDE fused pipe.

B. Concrete Thrust Blocks and Tie Rods:

1. Concrete shall be as specified in PennDOT Publication 408, Section 704 for Class

HES Concrete. Tie rods shall be constructed of suitable metal. Metal harness of tie rods shall be galvanized or otherwise rust proofed and shall be painted with bituminous coating after installation.

C. See Standard Construction Details for additional dimensions and reinforcement information.

2.8 WASTEWATER COMBINATION AIR RELEASE VALVES

A. The wastewater combination air release valve (ARV) shall be specifically designed for use in wastewater applications and have a working pressure range from 1.5 - 250 psi. Its design shall prevent contact between the wastewater and the sealing mechanism at pressure up to its rated working pressure and shall ensure drip tight sealing when back pressure at the seal is 1.5 psi and higher.

1. The spring guided rod and the bottom float assembly shall be able to move freely while the valve is closed and perform without jamming or allowing air escape under vibrations or bottom float bouncing related to the turbulence from pump starts and stops and/or flow fluctuations.

B. The ARV shall automatically discharge air and gas from a filling system, shall admit air into the system at drainage and at water column separation, and shall continuously release accumulated air and gas when the system is pressurized and operational.

C. The 316 stainless steel body, shall be conical in shape for assuring a larger air pocket while maintaining a relatively short profile, assuring a larger chamber for non-restrictive movement of the float, and providing an outward slanting wall to deter accumulation of grime and grease.

D. Manufacturers:

1. A.R.I., Combination Air Release Valve for Wastewater.

2. Or approved equal.

E. ARV Specifications:

1. Bolt, nut, and washer(s) shall be made of stainless steel.

2. Cover shall be made of reinforced nylon or stainless steel.

3. Spring shall be made of stainless steel.

4. Float Assembly shall be made of polypropylene or stainless steel.

5. ARV shall have a non-slam discharge-throttling attachment.

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2.9 STAINLESS STEEL BALL VALVES

A. 2-piece or 3-piece full port design all stainless-steel construction. The valve must have an adjustable stem packing, reinforced PTFE seats, PTFE stem packing, PTFE thrust washer and PTFE body seal. Provide valves with threaded connections as needed.

2.10 VALVE BOXES

A. All valve boxes shall be placed so as not to transmit shock or stress to the valve and shall be centered and plumb over the operating nut of the valve. The ground in the trench upon which the CMU and valve boxes rest shall be thoroughly compacted to prevent settlement. The boxes shall be fitted together securely and set so that the cover is flush with the finished grade of the adjacent surface. A concrete pad as detailed on the Contract Drawings shall be provided around the valve box, sloped outwards.

B. All valve boxes shall consist of a plastic body with full flanged cast iron ring and cover and be suitable for use in traffic areas. Cast iron ring shall be marked “SEWER.” Valve box base shall be suitable for extra-large valves. Valve box shall be screw type and have a 5- 1/4” shaft diameter. Boxes shall be as manufactured by Highline Products, Bingham & Tylor, or equal.

C. Provide 5-1/4” shaft diameter valve boxes for all valves with 2” operating nuts.

D. Provide 2-1/2” shaft diameter valve boxes with locking lid for all curb stop valves. Provide two (2) keys for locking lid.

2.11 DUCKBILL CHECK VALVE

A. Duckbill, flanged, bolt-on check valve shall be constructed of suitable design for pipeline backpressure from Buna-N or EPDM material. Duckbill, flanged, bolt-on check valve shall be as manufactured by Onxy, Cla-Val, Tideflex Technologies, or equal.

2.12 SWING CHECK VALVES (4” AND LARGER)

A. Swing Check Valves larger than 3-inches shall be full body type with no internal moving parts except for the resilient disc, rated for a minimum working pressure of 250 psi, and shall be as manufactured by Val-Matic, Milliken Valve Company, or equal.

B. Valve ends shall be Standard American 125 pound flat-faced flanged, in accordance with

ANSI B16.1.

C. Valve body shall be constructed of ASTM A536 ductile iron with flow area equal to the nominal pipe inside diameter throughout the valve. Seat shall be designed for use sewerage and constructed on a 45-degree angle to minimize disc travel. A threaded port with pipe plug shall be provided on the bottom of the valve to allow for field installation of a backflow actuator or oil cushion device without special tools or removing the valve from the line.

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D. The top access port shall be full size, allowing removal of the disc without removing the valve from the line.

E. The disc shall be of one-piece construction; precision molded of Buna-N with an integral O-ring type sealing surface and reinforced with steel. Nylon reinforcements shall be provided in the flexible hinge area of the disc assembly.

F. A mechanical indicator shall be provided to provide disc position indication. The indicator shall have continuous contact with the disc under all operating conditions to assure accurate disc position indication.

G. Provide an oil cushion device to provide hydraulic control of the final 10% of valve closure and reduce valve slam and water hammer normally associated with rapid flow reversal conditions on pump shut down:

1. The oil cushion device shall consist of a high-pressure hydraulic cylinder, adjustable external flow control valve, oil reservoir, pressure gauge, stainless steel air inlet valve, and piping designed to control the closing speed of the last 10% of travel in 1-5 seconds.

2. A threaded bronze dashpot bushing unit with a grease fitting for lubrication shall connect the cylinder to the valve and shall have an air gap to prevent hydraulic fluid from entering the valve. A snubber rod fitted with O-ring seals and rod wipe scrapers shall make contact with the lower portion of the disc’s stainless steel strike plate.

H. Interior and exterior of valve shall be fusion bonded epoxy coated.

I. Each valve shall be hydrostatically tested, and seat tested to demonstrate zero leakage with test results being certified.

2.13 PLUG VALVES:

A. Plug valves shall be quarter-turn, non-lubricated eccentric type with flanged or MJ ends.

Eccentric plug valves shall be 100% port in all sizes suitable for wastewater service and meet AWWA C517. Flanges to be faced and drilled ANSI 125-pound standard. Mechanical Joint valves shall fully comply with ANSI/AWWA C111/A21.11.

B. Eccentric Plug Valves shall be as manufactured by Val-Matic, DeZurik, or equal.

C. Valve bodies of ASTM A126 Class B cast iron. Bodies in 4 inch and larger valves furnished with 1/8-inch welded overlay seat of not less than 90 percent pure nickel. Seat area to be raised, with raised surface completely covered with weld to insure that plug face contacts only nickel. Screwed-in seats not acceptable.

D. Plugs of ASTM A126 Class B cast iron or ASTM A536 ductile iron. Plug to have cylindrical seating surface eccentrically offset from center of plug shaft. Interference between plug face and body seat, with plug in closed position, to be externally adjustable in field with valve in line under pressure. Plug resilient faced with soft rubber.

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E. Valves to have permanently lubricated, metallic, radial shaft bearings supplied in the upper and lower bearing journals.

F. Valve shaft seals of multiple V-ring type, externally adjustable and repackable without removing bonnet or actuator from valve under pressure. Valves utilizing O-ring seals or non-adjustable packing not acceptable.

G. Valve pressure ratings to be 175 psi through 12 inches. Each valve given hydrostatic and seat test with test results being certified.

H. Interior of valves to be fluidized bed epoxy coated. Exterior of valves shall be fusion bonded epoxy coated.

I. Acceptable Manufacturers:

1. DeZurick, Series 100 Eccentric Valves

2. Pratt/Milliken Valve Company, Inc.

3. Or Approved Equal

2.14 RESILIENT SEATED KNIFE GATE VALVE

A. Valve shall be a bonnetless knife gate with a flat bottom gate.

B. Valve body shall be a one-piece casting of type 316 stainless steel for corrosive applications. Valve inside port diameter shall conform to MSS SP-81 requirements for resilient seated valves.

C. Seat shall be resilient seated.

D. Resilient seated valves shall have a perimeter seat design and provide bubble-tight shutoff in both directions to the full rating of the valve. The resilient seated valve shall be fully rated for dead end service and have no recommended flow direction and not require line pressure to seal. Resilient seat material shall be EPDM suitable for use with sanitary sewage.

E. Face-to-face dimension shall meet MSS SP-81 for knife gate valves.

F. Working pressure rating shall be rated accordingly for proposed pressure system.

G. Flange drilling shall be in accordance with ASME B16.5 class 150 and tapped for threads to allow vale to remain in place when air valve is removed.

H. Valve shall have a handwheel actuator.

I. The manual operated valve’s actuator yoke shall be 316 stainless steel. The stem shall be stainless steel.

J. Valve shall be a Model KGN Cast Stainless Steel Knife Gate Valves as manufactured by DeZURIK or approved equal knife type.

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2.15 TAPPING SLEEVES

A. Tapping sleeves shall be stainless steel tapping sleeves as manufactured by Romac Industries, Smith-Blair, or approved equal. All sleeves shall have a minimum working pressure of 150 psi minimum and meet the requirements of AWWA C223. All taps shall be machine drilled--no burned taps will be allowed.

B. Shell and lugs shall be type 316 and type 304L stainless steel per ASTM A240.

C. Bolts shall be type 316 stainless steel per ASTM A193.

D. Nuts shall be type 316 stainless steel per ASTM A194, and be coated to prevent galling.

E. Washers shall be type 316 stainless steel, per ASTM A240 with plastic lubricating washers.

F. Gaskets shall be SBR per ASTM D 2000 MAA 610 and be suitable for wastewater.

G. MJ bolts and nuts shall be heavy hex nuts, made of stainless steel.

H. Outlet shall be 304 stainless steel flange style.

2.16 MATERIALS

A. Bedding and Cover: AAHSTO No. 8 stone in accordance with Section 31 05 16 - Aggregates for Earthwork.

B. Soil Backfill from above Pipe to Finish Grade: Material of maximum size that can be readily placed in loose, 8-inch layers; conforming to the requirements below. Frozen material shall not be utilized:

1. Soil. Includes earth material with the following physical characteristics:

2. Gradation—More than 35% passing No. 200 sieve.

3. Minimum dry mass density—95 pounds per cubic foot determined according to

PennDOT PTM No. 106, Method B.

4. Maximum liquid limit—65, determined according to AASHTO T 89.

5. Plasticity index—not less than liquid limit minus 30, determined according to

AASHTO T 90 for soils with liquid limits of 41 to 65.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Verify that excavations, dimensions, and elevations.

B. Carefully examine each section of pipe and each pipe fitting before laying on conformance with the inspection requirements of the appropriate referenced standard.

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3.2 PREPARATION

A. Clean piping interior and mating surfaces of bell, spigot and gasket before laying. Maintain clean until completed work is accepted.

B. Perform trenching for sewer pipe and place pipe bedding as specified in Section 31 23

16.13 – Trenching.

C. Dig bell holes sufficiently large to permit proper joint making and to insure pipe is firmly bedded full length of its barrel.

D. Remove large stones or other hard matter capable of damaging pipe or of impeding consistent backfilling or compaction.

3.3 INSTALLATION

A. Bedding:

1. Excavate pipe trench as specified in Section 31 23 16.13 – Trenching.

2. Place bedding material at trench bottom.

3. Maintain optimum moisture content of bedding material to attain required compaction density.

B. Laying Pressure Piping:

1. All pipes shall be laid in strict accordance with the details the Standard

Construction Details. The laying of pipes in finished trenches shall be commenced at the lowest points so that the spigot end is pointing in the direction of flow. All pipes shall be laid with ends abutting and true to line and grade. They shall be fitted and match so that when laid in the work, they will form a sewer with a smooth and uniform invert. Sockets shall be carefully cleaned before pipes are lowered into trenches.

2. At all times when the work is not in progress, all open ends of the pipes and fittings shall be securely closed with tight stoppers so that no water, earth or other substances will enter the pipe or fittings. Any section of pipe already laid and found to be defective shall be taken up and replaced with new pipe.

C. Pipe Embedment:

1. Bedding:

a. All pipe shall be laid on a granular bedding of AASHTO #8 (formerly 1B) crushed stone or gravel. The bedding shall be hand compacted or compacted as directed by the Authority Representative or Engineer, and shall be a minimum depth of 6 inches or one-fourth the internal diameter whichever is greater. The bedding shall provide uniform longitudinal support to the pipe and shall be laid to provide the pipe grade and line.

2. Haunching:

a. Haunching is the area form the bottom of the pipe to the springline of the pipe. Material shall conform to PennDOT No. 1B crushed stone or gravel. This area shall be compacted to a minimum of 90 percent

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Standard Proctor Density by hand or mechanical tamping as directed by the Authority Representative or Engineer.

3. Final Embedment:

a. Final Embedment shall extent from the springline of the pipe to a depth of 6 inches minimum above top of the pipe. It shall be PennDOT No. 1B stone of gravel and shall be well compacted as directed by the Authority Representative or Engineer.

D. Joint Fusion Method – HDPE Pipe:

1. Butt Fusion:

a. The pipe shall be joined by the butt fusion procedure outlined in ASTM F2620 or PPI TR-33.

b. All fusion joints shall be made in compliance with the pipe or fitting manufacturer’s recommendations. Fusion joints shall be made by qualified fusion technicians per PPI TN-42.

2. Saddle fusion:

a. Saddle fusion shall be done in accordance with ASTM F 2620 or TR-41 or the fitting manufacturer’s recommendations and PPI TR-41.

b. Saddle fusion joints shall be made by qualified fusion technicians.

c. Qualification of the fusion technician shall be demonstrated by evidence of fusion training within the past year on the equipment to be utilized.

3. Socket Fusion:

a. Molded socket fusion fittings are only to be used for joining of HDPE pipe from 1/2 inch to 4” in size. Socket fusion shall be done in accordance with ASTM F2620 or the fitting manufacturer’s recommendations.

b. Socket fusion is the process of fusing pipe to pipe, or pipe to fitting by the use of a male and female end that are heated simultaneously, and pressed together so the outside wall of the male end is fused to the inside wall of the female end.

c. Qualification of the fusion technician shall be demonstrated by evidence of socket fusion training within the past year on the equipment to be utilized on the Project.

4. Electrofusion:

a. Electrofusion joining shall be done in accordance with the manufacturers recommended procedure. Other sources of electrofusion joining information are ASTM F1290 and PPI TN 34.

b. The process of electrofusion requires an electric source, a transformer, commonly called an electrofusion box that has wire leads, a method to read electronically (by laser) or otherwise input the barcode of the fitting, and a fitting that is compatible with the type of electrofusion box used.

c. The electrofusion box must be capable of reading and storing the input parameters and the fusion results for later download to a record file.

d. Qualification of the fusion technician shall be demonstrated by evidence of electrofusion training within the past year on the equipment to be utilized for this project.

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E. Thrust Restraints:

1. Pour concrete thrust blocks against undisturbed earth.

2. Locate thrust blocks at each elbow or change of pipe direction to resist resultant force and to ensure that pipe and fitting joints will be accessible for repair.

3. Protect metal-restrained joint components against corrosion by applying a bituminous coating or encasing metal area using concrete mortar.

4. Do not encase pipe and fitting joints to flanges.

5. Thrust blocks are not required when fused HPDE Pipe is utilized, with the exception of all terminal and inline cleanouts which must have thrust blocks.

6. Refer to the Standard details for construction of thrust restraints.

F. Cradles and Encasements:

1. Provide concrete cradles and encasements in accordance with the Standard

Construction Details.

3.4 FIELD QUALITY CONTROL

A. General Requirements: Conduct tests specified herein so that each pipeline installed in the Project is tested to the Authority Representative’s or Engineer's satisfaction:

1. Provide tools, materials (including water), apparatus and instruments necessary for pipeline testing.

2. Conduct tests in the presence of and to the satisfaction of the Authority

Representative or Engineer.

B. Alignment: After the gravity mains have been laid and backfilled, a light will be flashed between manholes or manhole locations to determine whether the alignment of the sewer is true and whether any pipe has been displaced, broken or otherwise damaged subsequent to laying. This test will again be conducted before final acceptance of the sewer:

1. Horizontal Alignment: Each section (manhole to manhole) of sewer shall show no less than a three-quarter (3/4) light circle throughout its length and any and all defects shall be corrected by the Contractor, to the satisfaction of the Authority Representative or Engineer, before the work shall proceed and before acceptance of and/or payment shall be made.

2. Vertical Alignment: No vertical displacement or misalignment will be accepted.

The Contractor, to the satisfaction of the Authority Representative or Engineer, shall correct all defects before the work shall proceed and before acceptance of and/or payment shall be made.

C. Initial Section Test:

1. To demonstrate acceptability of installed pipe materials and workmanship, construct and air test one sewer section from manhole to manhole using the pipe provided in the Work. Pre-testing such section prior to actual Initial Section Test not permitted.

2. Conduct Initial Section Test in same manner as Line Acceptance Test at the expense of the Contractor.

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3. Conduct said Initial Section Test for each size and type pipe material used in the Project prior to continued installation of same pipe.

4. Provide pipe manufacturer's representation during laying, backfilling and testing of Initial Sections Tests.

5. Failure of an Initial Section Test will be sufficient cause for the Authority Representative or Engineer to reject manufacturer and supplier of pipe regardless of cause of failure.

6. Sewer sections successfully tested as Initial Section Test will be retested under Line Acceptance Test.

D. Alignment Test for Pressure Lines:

1. Prior to backfilling of pressure lines, the joint alignment shall be inspected to assure the maximum deflection present in each joint does not exceed the manufacturer's recommendations.

2. Pressure lines that are a portion of a pump discharge system shall be inspected to assure the line is installed at a constant or increasing grade so as to eliminate the possibility for air accumulation at an intermediate high point.

3. Contractor shall correct any and all defects at no additional cost to the Authority and to the satisfaction of Authority Representative or Engineer prior to backfilling. This shall be completed before the work shall proceed and before acceptance of and/or payment shall be made.

E. Pressure Testing: As specified in Section 33 05 05.31 - Hydrostatic Testing.

3.5 PROTECTION

A. Protect pipe and aggregate cover from damage or displacement until backfilling operation is in progress.

B. Cap open ends of piping during periods of Work stoppage.

END OF SECTION