331116-Water-distribution.pdf

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WATER SYSTEM WATER DISTRIBUTION

SECTION 331116

WATER DISTRIBUTION

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes piping and appurtenances for potable-water service outside the treatment building. This Section also includes flushing, testing, and disinfecting waterlines.

1.2 SYSTEM PERFORMANCE REQUIREMENTS

A. Minimum Working Pressures: The following are minimum pressure requirements for piping and specialties, unless otherwise indicated:

1. Potable-Water Service: 160 psig.

1.3 SUBMITTALS

A. Product data which shows compliance with the reference standards for the following:

1. Pipe and fittings

2. Compression couplings for similar and dissimilar pipes

3. Suction Strainer

4. Insect Screen

5. Gradation of Rip-Rap

6. Curb Stop and Box

7. Sodium Ascorbate

1.4 QUALITY ASSURANCE

A. Comply with NSF 61, "Drinking Water System Components--Health Effects," for water service piping and specialties for domestic water.

B. Piping material shall bear label, stamp, or other markings of specified testing agency.

C. Comply with standards of authorities having jurisdiction for potable-water service piping, including materials, installation, testing, and disinfections.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Deliver piping with factory-applied end-caps. Maintain end-caps through shipping, storage, and handling to prevent pipe-end damage and to prevent entrance of dirt, debris, and moisture.

B. Protect flanges, fittings, and specialties from moisture and dirt.

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C. Store plastic piping protected from direct sunlight. Support to prevent sagging and bending.

1.6 COORDINATION

A. Coordinate piping materials, sizes, entry locations, and pressure requirements with building water distribution piping.

B. Coordinate with other utility work.

PART 2 – PRODUCTS

2.1 GENERAL

A. All waterlines, pipes, and fittings shall be new and unused, of the type, pressure rating or class, and size specified and as shown on the drawings.

2.2 HIGH DENSITY POLYETHYLENE (HDPE) PIPE

A. Pipe

1. High Density Polyethylene (HDPE) plastic pipe shall be PE-3408 as defined in

ASTM D1248, with a minimum cell classification of 345464C in accordance with ASTM D3350. The pipe shall be SDR11, 160-psig minimum pressure rating and comply dimensionally with ASTM D3035.

2. Pipe shall be manufactured in accordance with AWWA C901 for sizes 1/2” through 3”.

3. HDPE pipe larger than 2” diameter shall be provided in 40-foot lengths rather than rolls. HDPE pipe 2” and smaller shall be provided in rolls.

4. The joining method shall be butt fusion method and shall be performed in strict accordance with the pipe manufacturer’s recommendations. Butt fusion equipment used in the joining procedures shall be capable of meeting all conditions recommended by the pipe manufacturer, including but not limited to, temperature requirements, alignment, and fusion pressures. Ribbed steel inserts with stainless steel clamps are not approved for HDPE pipe.

5. The HDPE pipe shall be Geo-Flo pipe as manufactured by US Poly/JM Eagle, Hastings, NE (888) 437-9919 or Cenfuse pipe as manufactured by Centennial

Plastics LLC, Hastings, NE (866) 851-2227 or approved equal.

B. Fittings

1. PE fittings shall be made from material meeting the same requirements as the pipe.

2. Molded fittings shall be manufactured in accordance with either ASTM D2683 for socket fused or ASTM D3261 for butt fused and shall be so marked.

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3. All HDPE fittings shall have the same or higher pressure rating and compositions.

4. HDPE elbows, tees and reducers shall be as manufactured by Central Plastics

Co., Shawnee, OK (800) 654-3872 or approved equal.

2.3 GALVANIZED STEEL PIPE (GSP)

A. Pipe

1. ASTM A53 for pipe 4-inch diameter and smaller. Schedule 40.

2. Plain ends for joining with standard manufactured couplings.

3. Threaded ends shall meet requirements of ASME B1.20.1.

B. Fittings

1. ASTM A53. Schedule 40.

2. For threaded ends use Teflon thread sealing tape.

2.4 PIPE SLEEVE

A. PVC Schedule 80 Pipe: ASTM D 1785.

1. PVC, Schedule 80 Socket Fittings: ASTM D 2467.

2.5 COUPLINGS FOR SIMILAR OR DISSIMILAR PIPE

A. Compression type transition fittings for making connections between like and dissimilar pipe materials shall be designed to enable a variety of connections between polyethylene pipe to various pipes, sizes 2” and smaller, using the same central body and different inserts and collets. Fittings shall be Cepex performance series compression fittings as manufactured by Cepex Holding, S.A. and distributed by The

Lateral Connection Corp., Tallmadge, Ohio 44278 (866) 926-0187 or approved equal.

2.6 TRANSITION FITTING FROM HDPE TO TANK FLANGED NOZZLES

A. Transition from HDPE pipe to flanged nozzle on tank shall be made with an HDPE

IPS Flange Adapter and IPS Ductile Iron Back-Up Ring size for the HDPE pipe and nozzle, OD controlled and compatible with heat fusion. HDPE IPS Flange Adapter and IPS Ductile Iron Back-Up Ring shall be as manufactured by Independent Pipe

Products, Inc., Grand Prairie, TX (800) 499-6927 or approved equal.

2.7 FLAT STEEL SUCTION STRAINER

A. Zinc plated, 16-gauge, cold-rolled steel strainer with threaded end to attach to GSP pipe, part SSS6, as manufactured by Campbell Manufacturing, Inc., Bechtelsville, PA,

(800) 523-0224 or approved equal.

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2.8 INSECT SCREEN

A. 24-mesh woven wire cloth, type 304 stainless steel standard grade, non-corrodible.

2.9 RIPRAP AT OUTLET DRAIN

A. Stone for riprap shall be hard, dense, durable, angular in shape and resistant to weathering. Rounded stone or boulders will not be accepted as riprap material.

Individual stones shall have dimensions of 6” to 12”. Source for the stone shall be from rocks uncovered on site during construction operations or from an approved off-site source.

2.10 CURB VALVE

A. One-piece, closed-bottom body with tee head and plug integrally cast, TFE coated brass ball that is supported by two Buna-N-seats, and 300 psig maximum working pressure.

B. Minneapolis pattern.

C. Female iron pipe inlet by female iron pipe outlet.

D. Hole for attaching curb box rod or handle is provided in tee head.

E. Heavy cast bronze body construction conforming to AWWA C800.

F. Curb Valves shall be 300 psig Ball Curb Stops, sized for pipe diameter and material, both ends threaded with Minneapolis pattern top, model number 6105, as manufactured by A.Y. McDonald, Mfg. Co., P.O. Box 508, Dubuque, Iowa, (800)

292-2737, or approved equal.

2.11 MJ ADAPTER

A. Transition fitting between mechanical joint end on gate valve and same diameter polyethylene pipe.

B. Fusion fitting shall be a PE3408 butt fusion fitting manufactured in compliance with

ASTM D3261 for the IPS pipe side in.

C. Fitting shall be an MJ Adapter as manufactured by Performance Pipe, Plano, TX,

(800) 527-0662, or approved equal.

2.12 CURB BOX

A. Extension type curb box with threaded Minneapolis pattern base, cast iron base, steel pipe telescoping upper section.

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B. Curb boxes shall be manufactured by the same company as the curb stop and sized to fit curb stop. Box length, when installed, shall permit adjustment between 3 inches above and below final ground surface.

C. Lids shall be two-piece, cast iron with brass pentagon plug and have lettering

“WATER” permanently imprinted on them.

D. Box shall be equipped with stationary rod. The rod length shall be within 12 inches of the top of the box.

E. Curb box, complete with lid and stationary rod, shall be Minneapolis style, series number 5610 for 1” valves, series number 5611 for 2” valves, length as needed, as manufactured by A.Y. McDonald Mfg., P.O. Box 508, Dubuque, Iowa, (800) 292-

2737, or approved equal.

F. Three curb box keys shall be supplied to the Contracting Officer. Keys shall be as supplied by the curb valve and box manufacturer, and shall be model number 304B, 3-foot length, as manufactured by A.Y. McDonald Mfg., P.O. Box 508, Dubuque, Iowa,

(800) 292-2737, or approved equal.

2.13 AIR/ VACUUM VALVE

A. Air and Vacuum Valve

1. Valve shall operate by sealing the BUNA-N rubber outlet seat with a peripheral float as the liquid enters the valve chamber to raise the float. The valve shall satisfactorily withstand hydrostatic pressures of 300 psig. Cast iron body, top flange with brass trim, ½” NPT screwed inlet and outlet. Crispen A-5 valve beige color, standard pressure 20-150 psi, as manufactured by Multiplex

Manufacturing Co., Berwick, PA (800) 247-8258 or approved equal.

B. Post

1. As specified in Division 33 Water Hydrants.

2. Smooth four sides dimensional lumber, size as shown on the drawings.

C. Vent

1. Aluminum double outlet tank vent, ¾” t-style, with 20 mesh stainless steel screen. MB 155 tank vent as manufactured by Morrison Bros., Dubuque, IA,

(800) 377-5453 or approved equal.

2.14 UNDERGROUND DETECTION AND MARKING TAPE

A. Underground Detection and Marking tape shall meet the requirements of Division 31

Trenching, Bedding and Backfill for Utilities.

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2.15 CONCRETE

A. Concrete shall meet the requirements of Division 3 Cast-in-place Concrete.

2.16 SODIUM HYPOCHLORITE CHLORINE SOLUTION

A. The Contractor shall furnish air-tight containers of sodium hypochlorite, NSF approved solution, suitable for drinking water. All containers used to store sodium hypochlorite must also be NSF approved. The percentage of available chlorine shall be clearly shown on the containers.

PART 3 – EXECUTION

3.1 GENERAL

A. Construct the water system to the lines and grades shown or established in the field.

B. Stake locations of waterlines as shown on the drawings. Waterline location shall be approved by Contracting Officer before installation of waterline.

C. All water line installation shall be graded to drain.

D. All pipe, fittings, and appurtenances shall be handled and laid in strict conformance to the manufacturer’s recommendations.

E. Daylight drains, valves, and other regulating and controlling devices shall be installed in the line where called for on the drawings.

F. The interior of all pipe, fittings, and other accessories shall be kept as free as possible from dirt and foreign matter at all times. Each piece of line as it is laid shall be cleaned of all debris. When the pipeline has become dirty on the inside during shipment or storage, it shall be swabbed out by drawing a damp swab through the line before lying. Care shall be exercised to keep all joining surfaces clean. Any pipe with contaminated or damaged joining surfaces, which cannot be satisfactorily cleaned or repaired, shall be discarded. Under no circumstances shall pipe be laid in water, and no pipe shall be laid when trench conditions or the weather is unsuitable for such work. At all times when work is not in progress, all open ends of the pipe and fittings shall be securely closed to the satisfaction of the Contracting Officer so that no trench water, rodents, earth, or other substance will enter the pipe or fittings.

G. Any section of pipe already laid and found to be defective shall be taken up and replaced with new pipe at the Contractor’s expense.

H. Water mains crossing sewers should be laid to provide a minimum vertical distance of

18 inches (46 cm) between the outside of the water main and the outside of the sewer.

This should be the case where the water main is above the sewer. At crossings, one

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full length of 18 foot (5.5 m) water pipe should be located so both joints will be as far from the sewer as possible. Special structural support for the water and sewer pipes may be required.

I. Maintain a 10 foot horizontal separation between water and sewer lines. If the sewer line is less than 18 inches lower than the water line or if the sewer line is less than 10 feet horizontally from the water line, encase the joints of the sewer line in concrete.

J. Where water line crosses a road culvert, adjust grade of water line to provide a minimum of 12 inches of separation between the water line and culvert, maintaining slope of water line to daylight drain.

K. A minimum of one foot separation shall be maintained between electric and water lines in the same trench.

L. Bury piping with minimum cover as shown on the drawings.

3.2 EXCAVATION, TRENCHING AND BACKFILLING

A. Trenching and backfilling shall meet the requirements of Division 31 Trenching, Bedding and Backfill for utilities.

3.3 PIPE ALIGNMENT AND GRADE

A. Complete water system shall be constructed to drain by gravity to daylight drains for winter campground shutdown. Waterlines shall be constructed to drain at the minimum grade indicated on the drawings. Waterlines not meeting this requirement shall be removed by the Contactor and replaced at no cost to the government.

B. Pipelines may be relocated slightly, if necessary, to avoid existing obstacles. However, all lines shall be installed to slope towards daylight drains as shown on the drawings.

C. Deflections from a straight line or grade, as required by vertical curves, horizontal curves, or offsets, shall not exceed the manufacturer's recommended maximum joint deflection or curvature for their pipe. If the alignment requires curvature or deflections in excess of these limitations, the Contractor shall provide special bends, standard fittings, or a sufficient number of shorter lengths of pipe to provide angular deflections at the joints within the limit set forth by the manufacturer.

D. Bends resulting in tension on joints will not be allowed.

3.4 CUTTING AND HANDLING OF PIPE

A. Cutting of pipe for closure pieces or for other reasons shall be done in a neat manner by methods, which will not damage the pipe. The pipe and fittings shall be handled in such a manner as to insure delivery and final placement in good, undamaged

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condition. Particular care shall be exercised not to injure the pipe surfaces or coatings.

Damaged pipe shall not be used in the work.

3.5 LAYING PIPE

A. No pipe shall be placed in the trench until the Contracting Officer has approved the trench and bedding.

B. Each section of the pipe shall rest upon the pipe bed for the full length of its barrel.

C. Backfill the pipe within 24 hours after installing the pipe in the trench, leaving the joints and one foot of pipe on each side of each joint exposed until testing is complete.

D. When work is not in progress, securely close open ends of pipe and fittings.

E. When high density polyethylene pipe is used, it shall be weaved in the trench to provide horizontal slack in the line for expansion and contraction.

F. High density polyethylene pipe shall be allowed to cool to within 20°F of the shaded trench bottom temperature before backfilling.

3.6 HDPE PIPE INSTALLATION

A. Install HDPE pipe according to ASTM D2774 and ASTM F645.

3.7 JOINT CONSTRUCTION

A. Joints shall be made using jointing materials and applied with the proper accessories, in accordance with the manufacturer’s instructions. The joints shall be adjusted and the work performed in a manner so as to obtain the degree of water tightness required.

If pipe and fittings are assembled with lubricant, it must be nontoxic. Where connections are made between new work and existing lines, the connections shall be made by using special fittings to suit the actual conditions.

B. Threaded Joints:

1. Thread pipes with tapered pipe threads according to ASME B1.20.1, apply tape and apply wrench to fitting and valve ends into which pipes are being threaded.

2. Exposed threaded pipe joints on galvanized steel pipe shall be painted with mastic following the manufacturer’s application procedures.

3. Field cut ends shall be squared off by grinding or filing; ends shall be reamed with all chips and flakes removed.

4. Field cut threads or machined joints shall be made with sharp tools to sharp finished ends.

C. PE Heat-Fusion Joints

1. According to ASTM D 2657 and piping manufacturer's written instructions.

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2. The joining method shall be butt fusion method and shall be performed in accordance with the pipe manufacturer's recommendations. Butt fusion equipment used in the joining procedures shall be capable of meeting all conditions recommended by the pipe manufacturer, including but not limited to, temperature requirements, alignment, and fusion pressures.

3. Personnel trained in butt fusion techniques by the manufacturer of the pipe, shall supervise or perform butt fusion operations.

4. Butt fusion shall be performed between pipe ends or pipe ends and fitting outlets, of like outside diameter and wall thickness, SDR or DR. Butt fusion joining between same diameters but unlike wall thickness shall not be permitted.

Transitions between unlike wall thickness shall be made with a transition nipple

(a short length of the heavier wall pipe with one end machined to the lighter wall) or by mechanical means.

5. Branch connections to the main shall be made with polyethylene fittings, and butt fused.

6. On every day butt fusions are to be made, the first fusion of the day shall be a trial fusion. The trial fusion shall be allowed to cool completely, and then fusion test straps shall be cut out. The test strap shall be 300 mm (12") (min) or 30 times the wall thickness in length with the fusion in the center, and 25 mm (1")

(min) or 1.5 times the wall thickness in width. Bend the test strap until the ends of the strap touch. If the fusion fails at the joint, a new trial fusion shall be made, cooled completely and tested. Butt fusion of pipe to be installed shall not commence until a trial fusion has passed the bent strap test.

D. Dissimilar Materials Piping Joints

1. Polyethylene pipe and fittings may be joined to other materials by means of couplings designed for joining polyethylene pipe to another material. Couplings shall be fully pressure rated and fully thrust restrained such that when installed in accordance with manufacturer’s recommendations, a longitudinal load applied to the coupling will cause the pipe to yield before the coupling disjoints.

2. Use adapters compatible with both piping materials, OD, and system working pressure.

3.8 BRANCH CONNECTIONS

A. Branch connections to the main shall be made with tees.

B. Horizontal tees for waterline laterals shall not be permitted. The branch side of tees shall be up when drainage is toward the tee and down when drainage is away from the tee.

C. Waterline tees shall be the same diameter as the largest pipe connected to the tee.

3.9 PIPE SLEEVE INSTALLATION

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A. Install waterline in pipe sleeve where shown on the drawings.

3.10 INSTALLATION OF CURB STOP

A. Each curb stop shall be housed in a curb box as specified.

B. Comply with manufacturer’s written instructions. Install underground curb valves with head pointed up.

C. Install concrete pad around top of box as shown on the drawings.

D. Scribe concrete with a line showing the alignment of the underground pipe and direction of open/close of the valve.

3.11 DAYLIGHT DRAIN

A. Transition from water system piping to galvanized steel pipe 10-feet from atmospheric outlet of daylight drain.

B. Install suction strainer and insect screens on the atmospheric outlet of daylight drains.

Attach insect screens to pipe with stainless steel hose clamps.

C. Minimum grade of slope of drain shall be 1%.

D. Place riprap securely around outlet with a minimum 6” air gap.

3.12 FINAL PIPE CLEANING AND FLUSHING

A. Before testing, clean new water distribution piping systems and parts of existing systems that have been altered, extended, or repaired by high pressure water jet or mechanical means.

B. During the flushing operation, operate all valves, hydrants, hose bibs and other outlets.

C. Flush system with clean potable water until dirty water does not appear at points of outlet.

3.13 PRESSURE TESTING WATERLINES

A. The Contractor shall conduct pressure and leakage tests on all newly installed or laid pipeline, or any valved section thereof. Pneumatic testing will not be allowed.

B. Conduct piping tests before joints are covered and after thrust blocks, if required, have hardened sufficiently. Joints shall remain uncovered until testing is completed satisfactorily.

C. The Contractor shall furnish the pump, pipe, gauge, measuring device, connections, and all other necessary apparatus, and shall furnish the necessary personnel to conduct

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the tests. All equipment, gauges, and attachments shall be subject to approval by the

Contracting Officer.

D. The Contracting Officer shall be present during the testing period.

E. Test all newly constructed portions of the water system, including water mains, service lines, fittings, valves, and hydrants.

F. Conduct piping tests before joints are covered. Joints shall remain uncovered until testing is completed satisfactorily.

G. Use only potable water.

H. Waterlines shall be tested in sections not to exceed 2,000 ft in length or a maximum pressure differential of 30 psi in the test section.

I. Test Procedure

1. Slowly fill each valved or plugged test section of pipe with water. The line shall be filled by means of a pump connected to the pipe. Operate all hydrants and taps to bleed entrapped air from the test section. Operate the pump continuously during bleeding operations. The pump shall take suction from a small auxiliary tank for measuring the water the water pumped into the test section.

2. Raise the internal pressure of the system by pumping in water. Increase pressure in 50-psig increments and inspect each joint between increments. The test pressure inside the utility building shall be 100 psi. Isolate the hydropneumatic tank while performing line testing. The test pressure for the campground distribution systems shall be 125 psi.

3. The system should be allowed to stabilize for 3 hours at the test pressure before conducting the hydrostatic test. Make up liquid may be added during this time to return to test pressure.

4. After obtaining the approved test pressure record the water level in the auxiliary tank.

5. The test phase follows immediately and shall last 2 hours.

6. Immediately following the initial expansion phase, reduce the test pressure by 10 psi, and stop adding test liquid. If the test pressure remains steady (within 5% of the target value) for one (1) hour, no leakage is indicated.

J. Leakage shall be verified by the Contractor and the CO.

K. If there is leakage in excess of the above requirements, the Contractor shall, at his own expense, locate and replace any defective pipe, fittings, valves, joints, and hydrants as required, until the leakage is within the specified allowance. All visible leaks are to be repaired regardless of the amount of leakage. Flush the system, and repeat the pressure test until leak is repaired.

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L. No paints, asphalts, tars, enamels, or other types of pipe compounds shall be used to eliminate leaks.

M. Backfill for waterlines shall be completed after the Contracting Officer approves testing.

N. The Contractor shall furnish a written report to the Contracting Officer describing the results of each test. The report must identify the specific portions of the pipeline tested, the pressure, the duration of the tests, and the amount of leakage.

3.14 DISINFECTION OF WATERLINES

A. Disinfection by chlorination shall be performed after flushing and pressure testing are completed and approved by the Contracting Officer.

B. Dosage: Provide chlorine solution with approximately 25 mg/l of chlorine for disinfecting the water system unless otherwise directed by the Contracting Officer.

C. Procedure: The entire system, including the storage tank, shall be filled with the disinfecting solution. Chlorine solution shall be placed in the system, at a location approved by the Contracting Officer. All taps, hydrants, and other outlets shall be opened and left open until chlorine is noticeable by odor or testing in the water coming from each. Immediately close taps, hydrants, and other outlets. An effort shall be made to limit the amount of chlorinated water discharged from the taps, hydrants and other outlets. Heavily chlorinated water shall not be drained into streams, rivers, or lakes; rather, open first those drains and hydrants which permit the longest travel time for the solution to reach surface waters.

D. Test Period:

1. Chlorinated water shall remain in the system a minimum of 24 hours, after which the system shall be examined by the Contracting Officer for residual chlorine. Chlorine residual at the end of the 24-hour period shall be a minimum of 10 mg/1.

2. If the minimum residual is not found present, the system shall be drained and the disinfection testing shall be repeated. When disinfection is complete and approved by the Contracting Officer, the system shall be flushed with potable water and the water leaving the lines shall have a residual chlorine concentration no higher than 1 mg/l.

3. When emptying the lines or tank after the 24-hour period, whether the system has passed or failed, the chlorine solution shall be neutralized before being discharged. Neutralize system by adding an NSF-certified sodium ascorbate

(Vitamin C) product to the storage tank in accordance with the table below.

Sodium ascorbate shall be Vita-D-Chlor Neutral, as manufactured by Integra

Chemical Company, Renton, WA (800) 322-6646, or approved equal. Add the sodium ascorbate to the storage tank, mix the water by mechanical methods and

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then release the water from the tank and flush the system. The formula for figuring the pounds of Vita-D-Chlor needed is: Gallons of water x chlorine residual (ppm)/ 45,400 = pounds of Vita-D-Chlor.

4. Residual chlorine at the outlets shall be less than 1 mg/l.

Amounts of Vitamin C (pounds) Required to

Neutralize Various Residual Chlorine

Concentrations in Different Volumes of Water

Volume of Water

(Gallons)

Chlorine Residual

(10 ppm)

Chlorine Residual

(25 ppm)

Chlorine Residual

(50 ppm)

1000 .22 pounds .55 pounds 1.1 pounds

2000 .44 pounds 1.1 pounds 2.2 pounds

4000 .88 pounds 2.2 pounds 4.4 pounds

5000 1.1 pounds 2.8 pounds 5.5 pounds

E. Bacteriological Examination: After the system has been disinfected as specified, the

Contracting Officer shall test the water for bacteriological contamination from representative points in the system. The coliform organisms shall be tested for presence/absence in accordance with State drinking water regulations. If coliform bacteria are present, testing shall be repeated in accordance with State drinking water regulations. If the report of this examination is unsatisfactory, the system shall be flushed and the disinfection procedure repeated until the results of bacteriological examinations are satisfactory.

F. The satisfactory quality of water delivered by the waterline should continue for a period of at least two full days, as demonstrated by laboratory examination of samples taken from taps along the system.

G. Bacterial testing of the water system will be the responsibility of the Forest Service.

H. Repeat disinfection of the water system shall be the responsibility of the Contractor with no additional expense to the Government.

END OF SECTION