SECTION 6

WATER DISTRIBUTION SYSTEM

MATERIALS FOR

CONSTRUCTION

SECTION 6

MATERIALS FOR CONSTRUCTION

A. GENERAL

1. Unless otherwise noted or approved by the Department all materials shall be manufactured in the United States. This section includes pipe and fitting material specification, joint material and encasement requirements.

B. MATERIALS

1. General:

a. All standards cited in the text refer to the latest revision of that standard under the same specification number or to superseding specifications under a new number.

b. All chemicals/products added to public water supply must be third party certified as meeting the specifications of ANSI/NSF Standard

60.

c. All materials/products that contact potable water must be third party certified as meeting the specifications of ANSI/NSF Standard 61.

d. The pressure rating of pipe must be capable of handling 1.5 times the normal working pressure.

e. No asbestos cement pipe allowed except in the repair of existing asbestos cement lines.

f. PVC pipe may not be used above grade.

g. All pipe fitting, packing, jointing materials, and valves must conform to

Section C of the AWWA Standards.

h. Previously used water lines that have been out of service will not be accepted by the Department.

C. POLYVINYLCHLORIDE (PVC) PIPE

1. Plastic pipe (PVC):

a. General:

1) Marked with National Sanitation Foundation approval at 18" intervals.

2) Gaskets to comply with ASTM F477.

a) Natural rubber gaskets are not acceptable.

b. 4" - 12":

1) Comply with ANSI/AWWA C900, Table 2, Pressure Class 235 marked with National Sanitary Foundation (NSF) approved at 18" intervals. Solvent-weld PVC pipe and fittings will not be accepted by the Department.

c. 14" and larger:

1) Comply with ANSI/AWWA C900 Table 2, pressure class 235 marked with National Sanitary Foundation (NSF) approved at 18" intervals. Solvent-weld PVC pipe and fittings will not be accepted by the Department.

D. DUCTILE IRON PIPE (DIP

1. All sizes of pipe shall be laying length of 18'-0" to 20'-0" and shall only be used on ditch crossings or when crossing above or below sewer mains.

2. Quality Assurance

a. Reference Standards of the American National Standards Institute

(ANSI)

1) A21.4

2) A21.10

3) A21.11

Cement-mortar lining for cast iron and ductile iron pipe and FBE fittings for water (AWWA

C104).

Fusion Bonded Epoxy fittings, 3" through 48" for water and other liquids (AWWA C116-09).

Rubber gasket joints for cast iron and ductile iron pressure pipe and fittings (AWWA C111).

4) A21.15

5) A21.50

6) A21.51

7) A21.53

Flanged cast iron and ductile iron pipe with threaded flanges (AWWA C115).

Thickness design of ductile iron pipe (AWWA

C150).

Ductile iron pipe centrifugally cast, in metal molds or sand lined molds, for water or other liquids (AWWA C151).

Fusion Bonded Epoxy (FBE) for 3" through

12" (AWWA C116-09).

8) B16.1 Cast iron pipe flanges and flanged fittings, Class 25, 125, 250, and 800.

b. Reference Standards of the American Water Works Association

(AWWA)

1) C600 Installation of ductile iron water mains and their appurtenances.

2) C651 Disinfecting water mains.

3. Wall thickness in accordance with Table 51.1 of ANSI/AWWA C151/A21.51 with working pressure of 150 psi, depth of cover indicated and Type 2 bedding conditions. Final pipe class shall be determined based on specific structural calculations as they relate to conditions encountered during design. The Department reserves the right to designate the final pipe thickness.

a. 4" - 12" class 350

b. 14" - 64" pressure class 250

c. Flanged pipe shall be class 53 (minimum)

d. Underwater pipe shall be a minimum of class 52.

4. Use cement mortar lining: ANSI/AWWA C104/A21.4, standard thickness.

5. Use mechanical or push-on joints: ANSI/AWWA C111/A21.11 as modified by ANSI/AWWA C151/A21.51.

6. Use rubber gaskets and lubricant: ANSI/AWWA C111/A21.11.

a. Natural rubber gaskets are not acceptable.

7. No metric sized pipe shall be permitted.

8. All pipe to be shipped with gaskets, glands, and bolts unless specified otherwise. High tensile strength tee bolts and nuts shall be low alloy steel.

Bolted joints for underwater pipe shall be furnished with 316 stainless steel nuts and bolts. The 316 grade shall be clearly indicated with marks on the bolt and nut.

9. All pipe lengths must be tested to 500 psi working pressure prior to shipping.

10. Threaded flange pipe must be tested after the installation of the threaded flange. Pipe with threaded components, i.e. flange or bell must be tested after installation of threaded component.

11. All new transmission water mains must be permanently marked in the Department’s easement with Department-approved above-ground markers.

12. Acceptable products: American Cast Iron Pipe Company, Griffin Pipe Company, U.S. Pipe Company, and McWane Ductile

E. HIGH DENSITY POLYETHYLENE (HDPE) PIPE

3. High Density Polyethylene (HDPE) pipe shall be used only for directional drilling under creeks or marsh crossings unless otherwise approved by the

Department.

2. Comply with AWWA C-906, SDR 11 and working pressure of 160 psi minimum.

3. The pipe supplied shall be SDR high performance, high molecular weight, high density polyethylene pipe, and shall conform to ASTM D 1248 (Type III

C, Category 5, P34). Minimum cell classifications values shall be 345434C as referenced in ASTM D-3350 - latest edition. All pipe resin shall be manufactured by the same company that manufactures the pipe itself in accordance with these specifications to insure complete resin compatibility and total product accountability. The fittings supplied in this specification shall be molded or manufactured from a polyethylene compound having a cell classification equal to or exceeding the compound used in the pipe. To insure compatibility of polyethylene resins, all fittings supplied under this specification shall be of the same manufacture as the pipe being supplied.

4. Physical properties:

a. The pipe shall conform to the physical properties as described herein.

b. Typical pipe physical properties:

Property Test Method Unit Value

Density ASTM Method gms/cc 0.955

Melt Index ASTM D-1238 gms/10 min

(190/2.16)

Environmental Stress Cracking Resistance:

Condition A, B, & C, F-0 ASTM D-1693 hrs >5000**

Compressed Ring, F-60 ASTM F-1248 hrs >1500

Tensile Strength, Yield ASTM D-638 psi 3200

Type IV Specimen (2"/min)

Elongation at Break ASTM D-638 % >750

Type IV Specimen (2"/min)

Victate Softening Temp ASTM D-1525 F 257

Brittleness Temp ASTM D-746 F <-180

Flexural Modulus ASTM D-790 psi

135,00

Modulus of Elasticity ASTM D-638 psi 130,000

Hardness ASTM D-2240 Shore D 65

Linear Thermal

Expansion Coef. ASTM D-696 in./in./F 1.2x10-4

Thermal Conductivity Dynatech-Colora BTU, In./Thermoconductor ft./2hrs/F 2.7

Long Term Strength:

73F ASTM D-2837 psi 1600

UV Stabilizer ASTM D-1603 %C 2.5

Material Cell Classification ASTM D-1248 345434C

Material Description PPI Recommendation PE 3408

5. Quality control:

a. The resin used for manufacture of the pipe shall be manufactured by the pipe manufacturer, thus maintaining complete control of the pipe quality. The pipe shall contain no recycled compound except that generated in the manufacturer’s own plant from resin of the same specification from the same raw material. The pipe shall be homogenous throughout and free of visible cracks, holes, foreign inclusions, or other deleterious defects and shall be identical in color, density, melt index, and other physical properties.

The polyethylene resin used shall have all ingredients pre-compound prior to extrusion of pipe, in plant blending is not acceptable. Owner may request, as part of the quality control records submittal, certification that the pipe produced is represented by the quality assurance testing. Additionally, test results from manufacturer’s testing or random sampling by the Engineer that do not meet appropriate ASTM standards or manufacturer’s representation, may be cause for rejection of pipe represented by the testing. These tests may include density and flow rate measurements from samples taken at selected locations within the pipe wall and thermal stability determinations according to ASTM D 3350, 10.1.9. Certified lab data may be requested to verify the physical properties of the materials supplied under this specification or may take random samples and have them tested by an independent laboratory.

6. Rejection:

a) The Department reserves the right to reject any polyethylene pipe and fittings failing to meet any of the requirements of this specification.

F. FUSABLE POLYVINYLCHLORIDE (FPVC) PIPE

FPVC pipe shall be used only for directional drilling under creeks or marsh crossings. All other uses of FPVC pipe shall be approved by the

Department.

2. Comply with AWWA C900 for 4”-12” diameter pipe and AWWA C900 for 14” and larger diameter pipe. Comply with manufacturer’s specifications.

FPVC pipe shall be extruded with plain ends. The ends shall be square to the pipe and free of any bevel or chamfer. There shall be no bell or gasket of any kind incorporated into the pipe.

FPVC shall be blue in color for potable water use.

Unless otherwise specified, FVPC pipe lengths shall be assembled in the field with butt-fused joints. The Contractor shall follow the pipe supplier’s guidelines for this procedure.

F. SERVICE PIPE

1. Minimum size - 3/4"

2. High molecular weight polyethylene pipe complying with ASTM D1248, Type III, and AWWA C-901 for flexible pipe with CTS.

a) Pipe shall be stamped with National Sanitation Foundation approval for use with potable water at 18" intervals.

G. FITTINGS AND SPECIALS

1. General:

a. Cast iron fittings are not acceptable.

b. Comply with ANSI A 21.4 (AWWA C104), ANSI A 21.53 (AWWA C153), and ANSI A 21.51 (AWWA C151)

2. PVC

a. Plastic pipe 4" and larger:

1) Use 150 psi pressure rated FBE ductile iron fittings or specials unless otherwise indicated, complying with

ANSI/AWWA C110/A21.10.

2) Provide adapter glands, gaskets, etc. as required to accommodate any differences in pipe and fitting dimensions.

b. Plastic pipe 3" and smaller:

1) Use PVC fittings, 160 psi at 73F pressure rating, joint design to conform to pipe joints.

3. Ductile iron pipe:

a. Use 250 psi pressure rated ductile iron FBE fittings or specials unless otherwise indicated.

1) ANSI/AWWA C110/A21.10.

2) ANSI/AWWA C153.

b. Fittings for use with push-on joint pipe.

1) ANSI/AWWA C111/A21.11.

c. Compact fittings for piping 3" - 16" may be provided in accordance with ANSI/AWWA C153/A21.53.88.

d. Use cement mortar lining: ANSI/AWWA C104/A21.4, Standard thickness.

4. No metric sized fittings shall be permitted.

5. All fittings to be shipped with gaskets, glands, nuts, and bolts unless specified otherwise. Nuts and bolts shall be low alloy steel. Tee bolts and nuts shall be high tensile strength, low alloy steel or 316 stainless steel.

Material shall be marked on the nuts and bolts.

6. Acceptable products: American Cast Iron Pipe Company, Griffin Pipe Company, U.S. Pipe Company, Tyler Pipe Company, Harco Company, and McWane Ductile and Star Pipe Products.

H. JOINT MATERIAL

1. Push-on joints, mechanical joints and restrained joints conform to: ANSI

A21.11 (AWWA C111).

a. Lubricants

1) Lubricants which will support microbiological growth shall not be used for slip-on joints. Vegetable shortening shall not be used to lubricate joints.

2) Natural rubber or other material which will support microbiological growth may not be used for any gaskets, O-rings, and other products used for joining pipes, setting meters or valves, or other appurtenances which will expose the material to the water.

2. Flanged joints conform to ANSI A21.15 (AWWA C115) ANSI B16.1 Faced and drilled 125 pound.

3. Bolts, Nuts, and All-Threaded Rod:

a. Tee bolts shall be made of high tensile strength low alloy steel containing a minimum of 0.50 percent copper, or high-strength low carbon steel per ASTM A307, specifications for carbon steel externally threaded standard fasteners, Grade B, having a minimum yield strength of 45,000 psi.

b. Stainless steel materials shall be grade 316 and shall contain sufficient chromium to resist corrosion, oxidation, and rust.

c. Materials shall be sound, clean, and coated with a rust resistant lubricant.

d. Threads shall be in accordance with ANSI B1.1, Unified Inch Screw

Threads, and with B1.2, Screw Threads, Gages, and Gagging, conforming to the coarse thread series (UNC) Unified Coarse, with threads Class 2A internal and Class 2B external.

e. Bolts ¾” and smaller shall be furnished with heavy hex heads conforming to ANSI B18.2.1.

f. Bolts larger than ¾” may have either standard or heavy hex heads conforming to ANSI B18.2.1.

g. Bolts and nuts shall be a high strength, low alloy steel tee head or hex head and shall comply with the dimensions outlined in

ANSI/AWWA C111/A.21.11. The steel shall have a minimum yield strength of 45,000 psi and contain the levels of carbon, manganese, sulfur, nickel, copper and chromium.

I. RESTRAINED JOINT PIPE AND FITTINGS

1. Provide restrained joint pipe and fittings on all piping at each fitting, valve, fire hydrant connection, and on the pipe joints to a minimum distance of 18' on each side of the fitting or valve for 12" piping and smaller and to a minimum distance of 36' on each side of the fitting for piping over 12" as a minimum. Use the ductile iron pipe research association (DIPRA) procedure for calculating restrained joint lengths.

2. Provide for use with mechanical joint pipe and fittings.

3. Quality Assurance:

a. Reference Standards of the American National Standards Institute

(ANSI).

1) A21.11

2) A21.53

3) A21.51

Rubber gasket joints for cast iron and ductile iron pressure pipe and fittings (AWWA C111).

Ductile iron compact FBE fittings for 3" through 48" (AWWA C153).

Ductile iron pipe centrifugally cast in metal molds or sand lined for water or other liquids (AWWA C151).

b. Reference Standards of the American Standards for Testing and

Materials (ASTM).

1) A536-84 Specifications for ductile iron castings (AWWA

C110).

4. Acceptable products:

a. American cast iron pipe: Fast Grip, Flex-Ring, Field Flex-Ring or Lock-Ring.

b. US Pipe: TR Flex or Field Loc 350 Gaskets.

c. Griffin Pipe: Snap-Lok Restrained Joint.

d. EBBA: Megalug Restraint Gland.

e. McWayne Ductile: TR Flex or Sure Stop

5. Restrained joint pipe will be indicated clearly on plans. The length of restrained joint pipe will be clearly marked on the drawings for all points where the direction or cross-sectional area of the pipe changes as well as at all bends, reducers, offsets, tees, wyes, deadends, valves, and fire hydrants.

Restrained lengths may be shown in plan view or in a table.

6. Components

a. Ductile iron glands sizes 4" through 24" shall conform to ASTM

A536-80 Specification for ductile iron casting.

b. Coating shall be a bituminous seal coat to conform with ANSI/AWWA C151/A21.51. Ductile iron pipe centrifugally cast in metal molds or sand lined molds for water or other liquids.

7. Joint Sizes

a. Dimensions of gland shall be such that it can be used with the standardized mechanical joint bell and tee-head bolts conforming to:

1) ANSI/AWWA C111/A21.11 Rubber gasket joints for gray iron and ductile iron pressure pipe and fittings.

2) ANSI/AWWA C153/A21.53 Ductile iron compact fittings for 3" through 48".

7. Other Requirements

a. The gland shall have a working pressure of at least 250 psi with a minimum safety factor of 2:1.

b. No metric sized nuts or bolts shall be permitted.

c. Twist off nuts shall be used to insure proper actuating of restraining devices.

J. COUPLINGS - 6" AND LARGER

1. Provide couplings where needed to make piping connections.

2. Provide full length mechanical joint ductile iron sleeve, 12" minimum length.

3. Provide cutting-in sleeve where installing fittings in an existing line.

a. Provide ductile iron with mechanical joint.

4. Provide restrained joint couplings: where restrained joints are indicated on the plans or when coupling is located within 18' for 12" piping and less and

36' for larger piping of a bend, tee or valve. For typical soil conditions, a safety factor of 2, and 150 psi pressure, the following table should be used for restrained joint couplings.

Pipe Diameter Length

6" 30'

8" 39'

10" 46'

12" 54'

14" 61'

18" 76'

24" 95'

5. Fittings to be installed in the new construction of water systems shall conform to those of standard design and in current inventory of the

Department. No special manufactured fittings will be allowed without prior approval of the Department.

K. PLUGS OR CAPS

1. Provide at all pipe ends and unused branches of fittings.

2. Tap and provide with 2" plug for installation of blow off.

3. Provide restrained joint.

L. METALLIC DETECTION TAPE AND TRACER WIRE

1. Provide 2" wide metallic detection tape and tracer wire on all buried piping.

a. Provide 5.0 mil overall thickness with no less than a 50 gauge solid aluminum foil core.

b. Foil to be visible from both sides.

c. No inks or printing extended to the edges of the tape.

d. Encase printing to avoid ink rub-off.

e. Tensile strength - 28 lbs/inch.

f. Use heat set mylar inks.

2. Locate 12" below ground surface in pipe trench.

3. Color to be Safety Precaution Blue.

4. Wording on tape to indicate “Potable Water” at no greater than 24" on center.

5. All water main installations shall also include the installation of metallic tracer wire laid 6" above the pipe.

LI. VALVES

1. General:

a. 3" through 12": Use gate valves.

b. 14" and larger: Use butterfly valves.

c. Open by turning counter clockwise with arrow cast in top indicating the direction of the opening.

d. End connections as required for the piping in which they are installed.

e. Two inch metal operating nut with arrow indicating direction of opening.

f. Use valves designed for a working pressure of not less than 150 psi unless otherwise specified herein.

g. Provide stem extensions on all valves where the top of the operator nut is located greater than 36" below the top of the valve box.

2. Quality Assurance

a. Reference Standards of the American National Standards Institute

(ANSI)

1) A21.5 Polyethylene encasement for gray and ductile cast iron piping for water and other liquids (AWWA C105).

2) A21.11 Rubber gasket joints for cast iron and ductile iron pressure pipe and fittings (AWWA C111).

3) B16.1 Cast iron pipe flanges and flanged fittings, Class 25, 125, 250, and 800.

b. Reference Standards of the American Water Works Association

(AWWA).

1) C600 Installation of Ductile Iron Water Mains and Their

Appurtenances.

2) 601 Disinfecting Water Mains

3) C504 Rubber Seated Butterfly Valves

4) C509 Resilient Seated Gate Valves

3. Gate valves:

a. Use resilient seated wedge valves: ANSI/AWWA C500/C509.

b. Internal ferrous metal surfaces to be fully coated with two part thermosetting epoxy conforming to AWWA C550 or fusion bonded, holiday free epoxy coating material to be AWWA and U.S. Food and

Drug Administration approved for use with potable water.

c. Provide fusion bonded or two part thermosetting epoxy coating on valve exterior conforming to AWWA C550.

d. Provide integrally cast bronze or stainless steel stem nut.

e. Design for external stem failure when excessive closing torque is applied with no failure of the pressure retaining parts.

f. Gate valves to have bevel gears with grease case, provide all necessary appurtenances for horizontal installation.

g. Provide valves with working pressure of not less than 250 psi and a

500 psig static test pressure.

h. Provide 316 stainless steel fasteners.

i. Ends shall be mechanical joint conforming to ANSI/AWWA

C111/A21.11.

j. Acceptable product: Mueller, American AVK, American-AD, or

American Flow Control.

4. Butterfly valves:

a. Provide butterfly valves conforming to AWWA Standard C504, latest revision, for Class 150B, unless otherwise specified.

b. Resilient seats are to be synthetic rubber (BUNA N).

c. Shafts to be turned, ground and polished, constructed of 18-8 Type

316 stainless steel.

1) Shafts to be of one piece design.

2) Attach disc to shaft with stainless steel tapered pins and locking nuts.

d. Spray coat all interior wetted ferrous surface with two component epoxy applied to a nominal thickness of 3 to 4 mils.

1) Coating material to be AWWA and U.S. Food and Drug

Administration approved for use with potable water.

e. Provide operators with not less than maximum operator torque, as determined in accordance with Appendix A of AWWA C504, to operate valves under actual line pressures and velocities.

1) Provide worm and gear, or traveling nut type, self-locking to prevent the valve disc from creeping or fluttering when it is in any intermediate position between open and closed.

2) Gear operators to be permanently lubricated, totally enclosed, with adjustable stops for the open and closed position, and except on units for buried service, shall have a valve disc position indicator.

f. Provide position indicator and extension shaft for all valves and operators.

1) Position indicator shall be hermetically sealed for installation in a

C.I. valve box.

2) Show valve disc position, direction of rotation and number of turns from full open to full close.

3) Shaft extension and pins to be stainless steel.

4) Base plate and housing to be aluminum.

5) Provide all bronze gearing.

6) Provide 2" AWWA square nut.

7) Approved manufacturer: Dyna-Torque, Inc. of Mukegon, Michigan.

g. Epoxy coated inside and outside conforming to AWWA C550.

h. Ends shall be flanged conforming to ANSI B16.1, Class 125.

i. Rated for a 150 psi working pressure.

j. Acceptable product: DeZurik, Mueller, American AD, Valmatic, or

Pratt.

5. Tapping Valves 12" and smaller shall conform to the following:

a. Resilient seat type conforming to AWWA C509.

b. Epoxy coated inside and outside conforming to AWWA C550.

c. Ends shall be flanged by mechanical joint conforming to ANSI B16.1, Class 125 and ANSI/AWWA C111/A21.11 respectively.

d. Rated for a 250 psi working pressure.

6. Tapping valves 14" and larger shall conform to the following:

a. Bronze seat, double disk type conforming to AWWA C500.

b. Epoxy coated inside and out conforming to AWWA C550.

c. Equipped with 4" by-pass valves.

d. Ends shall be flanged by mechanical joint conforming to ANSI B16.1, Class 125 and ANSI/AWWA C111/A21.11 respectively.

e. Allow full port opening cutters up to 24".

f. Rated for a 150 psi working pressure.

7. Other Requirements

a. All valves shall have Grade B cast iron or ductile iron bodies conforming to ASTM A126 or ductile iron ASTM A536.

b. All valves shall have a 2" square operating nut for buried service.

c. All valves shall have open left operation.

d. All valves shall be equipped with a non-rising stem.

e. All valves shall be constructed with 316 stainless steel bolts on bonnets, thrust collars, and operating nuts.

f. All valves shall be in conformance with the latest revision of all reference standards of AWWA or ANSI.

g. Valve boxes with drop covers will be of cast iron.

N. VALVE OPERATOR

1. Provide one T-handle operator for each ten buried valves with nut operator.

2. Operator to be epoxy coated.

O. VALVE BOXES

1. Provide at each buried valve.

2. Shall be full cast iron with cast iron covers suitable for heavy traffic use and conform to ASTM A-48, Class 20 Specifications.

3. Valve boxes shall be screw type and have a 5 ¼” inside shaft diameter.

4. Have the word “WATER” cast into the cover.

5. No part of the valve box is to rest on the buried valve.

6. Acceptable product: Products of Tyler Pipe/Utility Division #6850 Series and

Bingham and Taylor #4905 of U.S. manufacture only.

P. VALVE BOX PROTECTION RING

1. Provide at each valve box a precast concrete protection ring.

2. Provide two (2) rings of #3 reinforcing steel, one (1) 21" in diameter, and one

(1) 24" in diameter; or one (1) ring of #3 reinforcing steel, 22" in diameter with fibermesh concrete.

3. Inside dimensions to be 9 ¼”.

4. Outside diameter to be 27".

5. Provide 5" thickness at interior with a continuous slope to 2" thickness at the outside.

6. Minimum weight of 110 lbs.

Q. SERVICE AND TAPPING SADDLES

1. Provide of the following materials:

a. Body - Ductile Iron ASTM-A536.

b. Bales and straps - Type 316 stainless steel.

c. Studs - Type 316 stainless steel.

d. Hardware - Type 316 stainless steel.

e. Copper tube size (CTS).

2. Provide double strap for sizes 5" and larger.

3. Finish - Provide fusion bonded nylon to an average thickness of 12 mils.

4. Acceptable product: Smith Blair 317, Ford 202, Romac 202N, Mueller, or

JCM 406.

R. TAPPING SLEEVE AND VALVE

1. Tapping sleeve: provide stainless steel Tapping Sleeves: JCM Model 432

a. Provide ductile iron, split-type sleeve with flanged outlet.

b. Provide bolts, follower rings and gaskets on each end of the sleeve.

c. Provide for maximum working pressure of 150 psi.

d. Provide square head bolts with hexagonal nuts.

e. Provide ¾” NPT test plug.

2. Tapping valve:

a. Construct of material compatible with tapping sleeve.

b. Valve to conform to gate valve specifications.

c. Joints - Flange to tapping sleeve, for pipe end.

d. Acceptable product: Mueller, American Darling, AVK

S. AIR RELEASE VALVES

1. Provide cast iron body with stainless steel internal trim and float.

2. Provide stainless steel seat with BUNA-N rubber valve.

3. Provide 1" NPT inlet with 1" x ¾” bronze bushing.

4. Provide Crispin Type “N” Model PL10, Golden Anderson Figure 912.

a. ¼” orifice.

b. 0 to 150 psi working pressure.

c. 1" NPT connection.

5. Provide a heavy duty cast iron meter box to house valve.

T. CORPORATION STOPS

1. Acceptable product:

a. Ford Model F1100 with compression nut, gasket, and gripper inlet;

iron pipe thread outlet. IPT x grip nut.

b. Mueller Model H-15028; McDonald - 74701G.

U. CURB STOPS

1. Acceptable product:

a. Ford Model #B11, iron pipe threads inlet and outlet with lockwing.

b. Mueller, McDonald #76101W.

V. REPAIR COUPLINGS

1. Pipe larger than 2 ½”: Full length mechanical joint ductile iron couplings, 12" minimum length.

W. MISCELLANEOUS PARTS AND ACCESSORIES

1. Use standard commercial grade suitable for the type of installation or system involved, and conforming to the applicable standards and specifications of the AWWA.

X. CASING, SPACERS AND END SEALS FOR UTILITIES

1. General

a. Provide bore and jack with casing for pipes larger than 2".

b. Casing pipe to be 2" larger in diameter than the bell of the carrier pipe based on the following:

1) Casing pipe to be a minimum of 2" larger than the largest outside diameter of the carrier pipe (joints and couplings) if the carrier pipe is less than 6" in diameter. If the diameter of the carrier pipe is 6" or larger, the diameter of the casing pipe shall be a minimum of 4" larger than the largest outside diameter of the carrier pipe (joints and couplings).

2) The end of casing pipe to extend a minimum of six (6) feet from the edge of pavement/back of curb.

3) The top of the casing pipe shall be a minimum of four (4) feet below the crown of the finished asphalt roadway.

4) The top of the casing pipe shall be a minimum of two (2) feet below the design invert of roadside drainage ditches and pipes.

c. Carrier pipe shall be restrained joint.

2. Casing pipe for dry bores.

a. Steel complying with ASTM A139 for Grade B with minimum yield strength of 35,000 psi.

b. Provide ends suitable for field welding.

c. Minimum wall thickness as follows:

Diameter of Casing (Inches)

Minimum Wall Thickness (Inches)

6 thru 14 1/4

16 and 18 5/16

20 and 22 3/8

24 and 26 7/16

28 thru 32 1/2

34 thru 42 9/16

44 thru 48 5/8

50 thru 54 3/4

3. Pipeline Casing Spacers

a. Provide pipeline casing spacers for piping installed in casing.

b. Provide a minimum of one spacer per ten linear feet of pipe for ductile iron pipe and a minimum of one spacer per six linear feet for PVC pipe.

c. Provide spacer with shell of 14 gauge Type 316 stainless steel.

d. Provide shell liner of .090" thick PVC, 85-90 durometer.

e. Provide 5/16" stainless steel connecting bolts and lock nuts, minimum three (3) per flange.

f. Runners from 2" wide ultra high molecular weight polymer with a high resistance to abrasion and a coefficient of friction of 0.11-0.13 in accordance with ASTM D-1894.

g. Support runners on 14 gauge reinforced Type 316 stainless steel risers welded to shell.

h. All metal surfaces to be fully passivated.

i. The diameter as measured over the runners shall exceed the pipeline bell or coupling outside diameter.

j. Acceptable product: Cascade Manufacturing, BWM, or approved equal.

4. End Seals

a. Seal each end with brick and mortar to prevent entrance of foreign material.

Y. USE OF LEAD FREE SOLDER

1. Note: Section 1417 of the federal safe drinking water act has mandated that any pipe, solder, or flux used after June 19, 1986, in the installation or repair of public water systems and plumbing used for drinking water must be "lead free". The act defines "lead free" as less than 0.2 percent lead in solder and flux and less than 0.8 percent lead in pipes and fittings.

SECTION 7

CONSTRUCTION PROCEDURES

SECTION 7

CONSTRUCTION PROCEDURES

This section covers construction procedures normally required for work. It does not cover any special construction procedures which may be encountered for abnormal conditions.

Special construction procedures are to be presented to the Department by the

Developer’s Design Engineer.

A. HANDLING OF MATERIALS

1. Handle pipe so as to ensure delivery to the trench in sound, undamaged condition:

a. Carry pipe into position - do not drag.

b. Use pinch bars or tongs for aligning or turning the pipe only on the bare end of the pipe.

c. Use care not to injure pipe linings.

B. PIPE CUTTING

1. Cut pipe neatly and without damage to the pipe or lining.

2. Unless otherwise recommended by the pipe manufacturer, cut pipe with milling type cutter, rolling pipe cutter, or abrasive saw cutter. Do not flame cut. Use wheel cutters when practicable. Cuts must be even and perpendicular with length of pipe. Dress cut ends of pipe in accordance with manufacturer’s directives for the type of joint to be made.

C. LOCATING

1. Service lines:

a. Provide a water service to each subdivision lot.

b. Install service lines from the distribution main to the property lines at each lot, or at each location indicated or directed by the Engineer.

Normally installed on opposite side from the sewer service.

D. PIPE, VALVE, AND APPURTENANCE INSTALLATION

1. General:

a. The installation of water mains and appurtenances shall be conducted in accordance with the latest revision of Section C of the

AWWA Standards and/or the manufacture’s recommended installation procedures.

b. Lower pipe and accessories into trench by means of derrick, ropes, belt slings, or other equipment approved by the manufacturer.

c. Do not dump or drop any of the materials into the trench.

d. Except where necessary in making connections to other lines, lay pipe with the bells facing in the direction of laying.

e. Rest the full length of each section of pipe solidly on the pipe bed, with recesses excavated to accommodate bells, couplings, and joints.

f. Take up and relay pipe that has the grade or joint disturbed after laying.

g. Do not lay pipe in water, or when trench conditions are unsuitable for the work; keep water out of the trench until jointing is completed.

h. Securely close open ends of pipe, fittings, and valves when work is not in process.

i. Replace pipe where any part of coating or lining is damaged.

j. Bell pipe using manufacturer’s approved leverage bar.

1) Home line is to be clearly visible when pipe is joined.

2. Ductile iron pipe:

a. Mechanical and push on joints, install in accordance with

ANSI/AWWA C600.

b. Gaskets: Handle, lubricate where necessary and install in strict accordance with manufacturer’s recommendations.

3. PVC

a. Clean gasket, bell or coupling interior, especially groove area.

b. Lubricate and insert gasket as recommended by manufacturer.

c. Align spigot to bell, insert spigot into bell until it contacts gasket uniformly.

d. Bell pipe using manufacturer’s approved leverage bar.

1) Home line is to be clearly visible when pipe is joined.

4. FPVC

a. Pipe manufacturer’s and supplier’s procedures shall be followed at all times.

b. FPVC will be fused by qualified fusion technicians holding current qualification credentials for the pipe size being fused, as documented by the pipe supplier.

c. Only appropriately sized and outfitted fusion machines that have been approved by the pipe supplier shall be use for the fusion process.

This includes requirements for safety, maintenance and operation with minor modifications made for PVC.

d. FPVC pipe will be installed in a manner so as not to exceed the recommended bending radius.

e. Where FPVC pipe is installed by pulling in tension, the recommended

Safe Pulling Force, according to the pipe supplier, will not be exceeded.

4. Restrained joints:

a. Install in accordance with manufacturer’s instructions.

b. Tighten set screws to the manufacturer’s rated torque using a torque wrench.

1) If twist-off nuts are provided, tighten screws until nut breaks loose.

5. Underwater crossings:

a. Use ductile iron pipe, FPVC or HDPE.

b. Provide a minimum cover of two (2) feet.

c. Crossings greater than fifteen (15) feet in width:

1) Provide ball joint pipe for ductile iron pipe (DIP).

2) Provide valves at both ends of the water crossing.

3) A fire hydrant must be provided on the side opposite the supply service, sized in accordance with [R.61-

58.4(D)(7)[R.61-58.4(D)(13)(b)(iii)].

6. Above-water crossings:

a. Use ductile iron pipe with flanged joints.

b. Adequately support and anchor the pipe, protect from damage and freezing and be accessible for repair.

c. Hardware, straps, etc. to be 316 stainless steel.

7. Alignment and Grade

a. Fittings, valves and other appurtenances shall be located where shown on the approved plans, with the pipe being cut if necessary to assure accurate placement. Install the pipe, valves, and appurtenances to the alignment and profile shown on the approved drawings. Maintain a minimum depth of cover of 3' unless actual depths are shown on the approved drawings.

8. Rights-of-way, Easements, and Permits

a. It is the responsibility of the developer/engineer to obtain all necessary legal documentation and permits and advise Department of the status of each prior to the commencement of work. All installation is to be conducted within the parameters stipulated in the rights-of-way, easements, and permits, etc. Any damages caused by encroachment beyond the legal limits stipulated shall be the responsibility of the Developer and/or Contractor.

9. Protection of Pipe, Valves, and Appurtenances

a. Protection of Pipe, Gaskets, and Polyethylene Film

1) Store rubber gaskets and polyethylene film under cover and out of direct sunlight. Do not store nuts, bolts, glands, and other accessories directly on the ground. Keep inside of pipe and fittings free of dirt and debris.

b. Protection of Valves

1) Keep materials off the ground and keep interiors free of dirt and debris. Do not expose valve interior to direct sunlight.

10. Pipe, Valve, Blow-Off and Appurtenance Installation

a. Pipe Distribution

1) Deliver the pipe to the job site from the designated storage area in a safe manner.

b. Installation of Pipe and Valves

1) Inspect pipe for damage. Remove damaged and unacceptable pipe. Keep interior and joint surfaces clean and free of foreign materials. Install a M.J. or push-on type ductile iron plug whenever work stops for a period of a day or greater.

2) Provide and use proper implements, tools, and facilities for the safe and proper installation of the work. Lower all pipe, fittings, and appurtenances into the trench, piece by piece, by means of crane, slings, or other suitable tools or equipment, in such a manner as to prevent damage to the pipeline materials and protective coatings and linings. Do not drop or dump pipeline materials into the trench.

3) Remove all lumps, blisters, and excess bituminous coating from the bell-and-spigot ends of each pipe. Clean the spigot and the inside of the bell and wipe clean and dry. Insure surfaces are free from oil and grease before the pipe is laid.

4) Wipe the ends of mechanical joint pipe and fittings and rubber gasket joint pipe and fittings clean of all dirt, grease, and foreign matter.

c. Installation of Blow-Offs

1) All working parts shall be serviceable from above grade with no digging. See Detail Section.

d. Installation of Retainer Glands

1) Adjoining surfaces shall be clean, and lubricated meeting with requirements of ANSI/AWWA C111/A21.11.

2) Install using assembly recommendations established in

ANSI/AWWA C111/A21.11 as well as installation instructions provided by the manufacturer.

3) Megalug Retainer Glands - Tighten the T-head bolts to the normal range as indicated on the following table:

Pipe Size

(in)

Bolt Size

Range of Torque

(ft/lbs)

4"-24" ¾" 75-90

4) Retainer Glands - All set screws will be installed with proper torque as required by manufacturer:

Pipe Size

Bolt Size

Range of Torque

(ft/lbs)

4"-6" ¾” 80

5) All megalug retainer glands are furnished with rubber inserts to insure proper positioning. Do not remove them.

E. ALIGNMENT OF PIPE

1. Pipe lines intended to be straight shall be so laid.

2. Where vertical or horizontal alignment requires deflection from straight lines or grade, do not exceed 75% of maximum deflection recommended by the pipe manufacturer or AWWA Standard 600 Tables 5 and 6.

3. If alignment requires deflection exceeding recommended limits, furnish bends to provide angular deflections within the allowable limits.

F. SERVICE LINES

1. Locate service lateral within one (1) foot of property corner on opposite corner of sewer lateral.

2. Install polyethylene CTS flexible service lines in one continuous piece from main to metering point at right-of-way/property line.

3. Depth of the service connection shall be no less than the top of the main connection and shall be 12" deep at right-of-way line. Where service line crosses drainage structure (ditch), the service line will be at a depth of 18" below the design invert of such ditch.

4. Do not exceed an angle of 45 to the horizontal on the top.

5. Connections to mains:

a. PVC mains:

1. Use approved tapping saddle.

6. Provide corporation stops on all mains.

7. Terminate each service line with a Mueller institite ¼” NPT plug.

a. Mark with a wooden stake installed to 3' above grade.

G. SETTING VALVES AND VALVE BOXES

1. Center valve boxes on the valves, setting plumb. Valve box shall not at any point rest on any part of the valve.

2. Tamp earth fill around each valve box to a distance of 4' on all sides, or to the undisturbed trench face if less than 4'.

3. Install shaft extensions plumb without any binding.

4. Fully open and close each valve to assure that all parts are in working condition.

H. VALVE BOX PROTECTION RING

1. Place valve box protection ring around top of valve box as detailed.

a. Install ring level with top 1" above finished grade.

b. Top of ring to be level with or no more than 1" above the top of the valve box.

I. THRUST BLOCKS

1. The Department will approve the use of thrust block on a case by case basis.

2. Maximum soil pressure: 2000 lbs/sq ft. Minimize the use of thrust blocking by installing thrust restraint fittings when possible.

3. Minimum water pressure: 150 psi.

4. Safety factor: 2

5. Concrete: 3000 psi.

6. Locate thrust blocking between solid ground and the fitting to be anchored.

7. Provide 8 mil polyethylene film between the thrust block and fitting.

8. Place the base and thrust bearing sides of thrust blocking directly against undisturbed earth.

9. Sides of thrust blocking not subject to thrust may be placed against forms.

10. Place thrust blocking so the fitting joints will be accessible for repair.

J. JOINING PIPE, VALVES, AND APPURTENANCES

1. Mechanical, Push-On, and Restrained Joint

a. Join pipe with mechanical or push-on type joints in accordance with the manufacturer’s recommendations. Provide all special tools and devices, such as special jacks, chokers, and similar items required for proper installation. Lubricants for the pipe gaskets shall be used and shall be manufacturer’s standard. All mechanical joints used on hydrants, hydrant leads, taps and valves should have retainer glands.

2. Flanged

a. Prior to connecting flanged pipe, the faces of the flanges shall be thoroughly cleaned of all oil, grease, and foreign material. The rubber gaskets shall be checked for proper fit and thoroughly cleaned. Care shall be taken to ensure proper seating of the flange gasket. Bolts shall be tightened so that the pressure on the gasket is uniform. Torque-limiting wrenches shall be used to ensure uniform bearing insofar as possible. If joints leak when the hydrostatic test is applied, the gaskets shall be removed and reset and bolts re-tightened.

3. Pipe Bedding

a. Excavate trench bottom to provide a level cross section with vertical walls extending to the top of the pipe zone. Excavate evenly to provide smooth profile grade without holes and ridges. Keep trench dewatered.

b. Lay pipe on bedding such that it is continuously supported along the barrel, and is not bearing on the bell. After joint construction, place bedding material under bell. Unless otherwise directed, lay pipe with bell end facing in the direction of the laying.

4. Valves

a. Valves shall be carefully handled, cleaned and checked for operation prior to backfilling. Care shall be taken to insure that no dirt, rock, or other obstacles that would interfere with the operation are left in the valve. Valves shall be installed in a position such that the plane of operation or rotation for the operating nut is parallel to the ground surface.

b. Approximately ½” space shall be left to provide "play" for future removal of flanged valves.

5. Valve Box

a. A valve box shall be installed on each underground valve. They shall be carefully set, centered exactly over the operating nut and truly plumbed. The base shall be set, and so arranged that the weight of the valve box and superimposed loads will bear on the base and not on the valve or pipe. Extension stems shall be installed where depth of bury places operating nut in excess of 4' beneath finished grade.

K. ANCHORAGE

1. All pipelines shall be securely anchored. Retainer glands or megalugs shall be used on all mechanical joint fittings. All tees, plugs, caps and bends which are equal to or greater than 11¼ , and at other locations where unbalanced forces exist, must have acceptable thrust restraint.

2. Blocking

a. The concrete mix used for thrust blocking shall have 28 days compressive strength of not less than 3,000 pounds per square inch.

Place blocking between the undisturbed ground and the fitting to be anchored. Place the blocking so that the pipe and fitting joints will be accessible to repairs, unless otherwise shown.

3. Restrained Joints

a. Restrained joints shall be used in lieu of reaction blocking or in combination with blocking where appropriate and as designated by the Engineer or the Department.

L. WET TAP CONNECTIONS

1. Connections to existing water mains shall be done by use of wet taps using tapping sleeves or tapping saddles and tapping valves.

M. HIGHWAY AND RAILROAD CROSSINGS

1. General

a. Installation shall conform to the permits of all agencies having jurisdiction. Method of installation shall be specified by the Engineer.

2. Casing Pipe

a. Continuously weld lengths of casing pipe to the preceding section in accordance with AWS recommended procedures. Clean all debris from casing interior after casing installation is complete. Pressure grout any void areas apparent outside the casing.

N. INSTALLATION OF CASING, SPACERS AND END SEALS FOR UTILITIES

1. Locate to avoid interference with traffic, adjacent structures, etc. to such extent possible.

2. Excavate to required depth, providing sheeting and shoring necessary for protection of the work and for safety of personnel.

3. Maintain entry pits in dry condition by use of pumps, drains or other approved method.

4. Install casings by dry-boring through the casing while simultaneously jacking the casing.

5. Any proposed alternate method shall be approved in writing by the

Department.

6. Weld joints to provide a watertight joint.

7. Install casings for gravity sanitary sewer to grade, not varying more than

3/32" per foot of length from the indicated grade.

8. Installing pipe in casing:

a. Inspect carefully, insuring that all foreign material is removed from the casing and the casing meets alignment criteria for the type of carrier pipe being used.

b. For pressure systems, the casing deflection shall not exceed the maximum deflection recommended by the carrier pipe.

c. Install casing spacers on the carrier pipe per the manufacturer's instructions.

d. For sanitary sewer provide spacer sizing and length necessary to obtain the pipe slope and elevations as shown on the plans.

e. Provide restrained configuration.

f. Install the carrier pipe in the casing insuring each joint is pushed

"home" before the joint is installed into the casing.

9. Seal each end with brick and mortar to prevent entrance of foreign material.

O. PREPARATION OF RIGHT-OF-WAY

1. Remove obstructions within the trench area or adjacent thereto such as but not limited to tree roots, stumps, abandoned piling, buildings and concrete structures, logs, and debris of all types.

2. Properly dispose of obstructions removed from the excavation in accordance with local municipality directives.

3. Pavement, Curb, and Sidewalk Removal

a. Cut all bituminous and concrete pavements, regardless of thickness, and all curbs and sidewalks, prior to excavation of the trenches as specified in the South Carolina Department of Transportation Policy.

Width of the pavement cut shall be at least equal to the required width of the trench at ground surface. Pavement cut lines shall be even and parallel. Any ragged or uneven cuts shall be cut smooth before patching. Pavement and concrete materials removed shall be hauled from the site and not used for trench backfill.

P. TRENCH EXCAVATION

1. Trench Width

a. Maximum width of unsheeted trenches in which pipe is to be laid shall be 18" greater than the inside diameter of the pipe, but not less than that required for proper compaction around the pipe. Sheeting requirements shall be independent of trench widths.

b. The maximum trench width at the top of the pipe zone is limited to

1.33 times the pipe outside diameter plus 18".

c. In general, the maximum width at the top of the trench will not be limited, except where excess width of excavation would cause damage to adjacent structures or property. However, confine trench widths to dedicated rights-of-way or construction easements, unless special prior written agreements have been made with the affected property owner.

2. Grade

a. Excavate the trench to the lines and grades shown on the plans with proper allowance for pipe thickness and for pipe base or special bedding when required. If the trench is over excavated below the required grade, correct any part of the trench excavated below the grade with crushed stone or Class II backfill as specified herein.

b. Place the pipe bedding material over the full width of trench in compacted layers not exceeding 6" deep to the established grade.

3. Shoring, Sheeting and Bracing of Trenches

a. Sheet and brace the trench consistent with OSHA Regulations when necessary to prevent caving in during excavation or to protect adjacent structures, property, workmen, and the public. Increase trench widths accordingly by the thickness of the sheeting. Maintain sheeting in place until the pipe has been placed and backfilled at the pipe zone. Shoring and sheeting shall be removed in accordance with OSHA Regulations and, as the backfilling is done, in a manner that will not damage the pipe or permit voids in the backfill. All sheeting, shoring, and bracing of trenches shall conform to the safety requirements of the Federal, State or local public agency having jurisdiction. The most stringent of these requirements shall apply.

4. Dewatering

a. Provide and operate equipment adequate to keep all excavations and trenches free of water. Remove all water during period when concrete is being deposited, when pipe is being laid, during tunneling or jack and bore operations, during the placing of backfill, and at such other times as required for efficient and safe execution of the work.

Prevent settlement or damage to adjacent property. Dispose of water in a manner that will not damage adjacent property. When dewatering open excavations, dewater from outside the structural limits and from a point below the bottom of the excavation. Design a dewatering system to prevent removal of fines from existing ground.

5. Foundation Stabilization

a. When the existing material in the bottom of the trench is unsuitable for supporting the pipe, provide foundation stabilization as described here. Excavate below the pipe zone and backfill to specified grade with crushed stone or Class II backfill. Place the crushed stone or

Class II backfill over the full width of the trench and compact to the required grade.

Q. TRENCH BACKFILL

1. When backfill is mechanically placed, push the backfill material onto the slope of the previously placed and allow it to slide down into the trench. Do not push backfill into the trench in such a way as to permit free fall of the material until at least 2' of cover is provided over the top of the pipe. Under no circumstances allow sharp and/or heavy pieces of material to drop directly onto the pipe or the tamped material around the pipe. Do not use backfill material of consolidated masses larger than ½ cubic foot.

2. Backfill material types

a. Class I (Concrete) Backfill

1. Conform to ASTM C94, Alternate 3. Proportion to obtain a 28 day compressive strength of 2,500 pounds per square inch.

b. Class II Backfill

1. Material suitable for backfill in a properly dewatered trench shall consist of any of the following: Well graded coarse granular materials free of roots, branches, stumps, or other material not so suited, with maximum particle size not exceeding 1"; sands, silty-sand or clayey sands. Soils having more than 25% of its weight passing a No. 200 sieve shall not be used for backfill. Soils shall be compacted to 95% dry density (modified proctor).

c. Class III Backfill

1. Class III backfill will be used where suitable throughout the project and will generally be excavated trench material free of roots, branches, stumps, or other organic or unsuitable materials.

3. Backfill the trench for one (1) foot above the pipe with approved backfill material (Type II).