Attachment N - UFGS 33 40 00 Storm Drainage Utilities.pdf

SECTION 33 40 00 Page 1

SECTION TABLE OF CONTENTS DIVISION 33 - UTILITIES SECTION 33 40 00

STORM DRAINAGE UTILITIES

02/10

Table of Contents

PART 1 GENERAL

1.1 UNIT PRICES ......................... Error! Bookmark not defined.

1.2 REFERENCES

1.3 SUBMITTALS

1.4 DELIVERY, STORAGE, AND HANDLING

PART 2 PRODUCTS

2.1 PIPE FOR CULVERTS AND STORM DRAINS

2.2 PERFORATED PIPING ................... Error! Bookmark not defined.

2.3 DRAINAGE STRUCTURES ................. Error! Bookmark not defined.

2.4 MISCELLANEOUS MATERIALS

2.5 STEEL LADDER

2.6 RESILIENT CONNECTORS

2.7 EROSION CONTROL RIP RAP

PART 3 EXECUTION

3.1 INSTALLATION OF PIPE CULVERTS, STORM DRAINS, AND DRAINAGE

STRUCTURES

3.2 BEDDING

3.3 PLACING PIPE

3.4 JOINTING

3.5 DRAINAGE STRUCTURES

3.6 STEEL LADDER INSTALLATION

3.7 BACKFILLING

3.8 FIELD PAINTING

3.9 FIELD QUALITY CONTROL

3.10 PROTECTION

3.11 WARRANTY PERIOD

SECTION 33 40 00 Page 2

SECTION 33 40 00

STORM DRAINAGE UTILITIES

02/10

PART 1 GENERAL.

1.1 REFERENCES.

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO HB-17 (2002; Errata 2003; Errata 2005, 17th

Edition) Standard Specifications for

Highway Bridges

AASHTO M 167M/M 167 (2017) Standard Specification for

Corrugated Steel Structural Plate, Zinc-Coated, for Field-Bolted Pipe, Pipe-Arches, and Arches

AASHTO M 190 (2004; R 2017) Standard Specification for

Asphalt-Coated Corrugated Metal Culvert

Pipe and Pipe Arches

AASHTO M 219 (1992; R 2017) Standard Specification for

Corrugated Aluminum Alloy Structural Plate for Field-Bolted Pipe, Pipe-Arches, and

Arches

AASHTO M 243 (1996; R 2017) Standard Specification for

Field-Applied Coating of Corrugated Metal

Structural Plate for Pipe, Pipe-Arches, and Arches

AASHTO M 294 (2017) Standard Specification for

Corrugated Polyethylene Pipe, 300- to

1500-mm (12- to 60-in.) Diameter

AASHTO MP 20 (2013; R 2017) Standard Specification for

Steel-Reinforced Polyethylene (PE) Ribbed

Pipe, 300- to 1500-mm (12- to 60-in)

Diameter

AMERICAN CONCRETE INSTITUTE (ACI)

ACI 346 (2009) Specification for Cast-in-Place

Concrete Pipe

AMERICAN RAILWAY ENGINEERING AND MAINTENANCE-OF-WAY ASSOCIATION

SECTION 33 40 00 Page 3

(AREMA)

AREMA Eng Man (2017) Manual for Railway Engineering

ASTM INTERNATIONAL (ASTM)

ASTM A48/A48M (2003; R 2016) Standard Specification for

Gray Iron Castings

ASTM A123/A123M (2017) Standard Specification for Zinc

(Hot-Dip Galvanized) Coatings on Iron and

Steel Products

ASTM A536 (1984; R 2019; E 2019) Standard

Specification for Ductile Iron Castings

ASTM A716 (2018) Standard Specification for Ductile

Iron Culvert Pipe

ASTM A742/A742M (2020) Standard Specification for Steel

Sheet, Metallic Coated and Polymer

Precoated for Corrugated Steel Pipe

ASTM A760/A760M (2015, R 2020) Standard Specification for

Corrugated Steel Pipe, Metallic-Coated for

Sewers and Drains

ASTM A762/A762M (2019) Standard Specification for

Corrugated Steel Pipe, Polymer Precoated for Sewers and Drains

ASTM A798/A798M (2017) Standard Practice for Installing

Factory-Made Corrugated Steel Pipe for

Sewers and Other Applications

ASTM A807/A807M (2017) Standard Practice for Installing

Corrugated Steel Structural Plate Pipe for

Sewers and Other Applications

ASTM A849 (2015) Standard Specification for

Post-Applied Coatings, Pavings, and

Linings for Corrugated Steel Sewer and

Drainage Pipe

ASTM A929/A929M (2018) Standard Specification for Steel

Sheet, Metallic-Coated by the Hot-Dip

Process for Corrugated Steel Pipe

ASTM B26/B26M (2014; E 2015) Standard Specification for

Aluminum-Alloy Sand Castings

ASTM B745/B745M (2015) Standard Specification for

Corrugated Aluminum Pipe for Sewers and

Drains

ASTM C12 (2017) Standard Practice for Installing

Vitrified Clay Pipe Lines

ASTM C14 (2020) Standard Specification for Concrete

Sewer, Storm Drain, and Culvert Pipe

SECTION 33 40 00 Page 4

ASTM C14M (2020) Standard Specification for Concrete

Sewer, Storm Drain, and Culvert Pipe

(Metric)

ASTM C32 (2013; R 2017) Standard Specification for

Sewer and Manhole Brick (Made from Clay or

Shale)

ASTM C55 (2017) Standard Specification for Concrete

Building Brick

ASTM C62 (2017) Standard Specification for Building

Brick (Solid Masonry Units Made from Clay or Shale)

ASTM C76 (2020) Standard Specification for

Reinforced Concrete Culvert, Storm Drain, and Sewer Pipe

ASTM C76M (2020) Standard Specification for

Reinforced Concrete Culvert, Storm Drain, and Sewer Pipe (Metric)

ASTM C139 (2017) Standard Specification for Concrete

Masonry Units for Construction of Catch

Basins and Manholes

ASTM C231/C231M (2017a) Standard Test Method for Air

Content of Freshly Mixed Concrete by the

Pressure Method

ASTM C270 (2019) Standard Specification for Mortar for

Unit Masonry

ASTM C425 (2004; R 2013) Standard Specification for

Compression Joints for Vitrified Clay Pipe and Fittings

ASTM C443 (2020) Standard Specification for Joints for Concrete Pipe and Manholes, Using

Rubber Gaskets

ASTM C443M (2020) Standard Specification for Joints for Concrete Pipe and Manholes, Using

Rubber Gaskets (Metric)

ASTM C444 (2017) Standard Specification for

Perforated Concrete Pipe

ASTM C444M (2017) Standard Specification for

Perforated Concrete Pipe (Metric)

ASTM C478 (2018) Standard Specification for Circular

Precast Reinforced Concrete Manhole

Sections

ASTM C478M (2018) Standard Specification for Precast

Reinforced Concrete Manhole Sections

(Metric)

SECTION 33 40 00 Page 5

ASTM C506 (2020) Standard Specification for

Reinforced Concrete Arch Culvert, Storm

Drain, and Sewer Pipe

ASTM C506M (2020) Standard Specification for

Reinforced Concrete Arch Culvert, Storm

Drain, and Sewer Pipe (Metric)

ASTM C507 (2020) Standard Specification for

Reinforced Concrete Elliptical Culvert, Storm Drain, and Sewer Pipe

ASTM C507M (2020) Standard Specification for

Reinforced Concrete Elliptical Culvert, Storm Drain, and Sewer Pipe (Metric)

ASTM C655 (2014) Reinforced Concrete D-Load Culvert, Storm Drain, and Sewer Pipe

ASTM C700 (2013) Standard Specification for

Vitrified Clay Pipe, Extra Strength, Standard Strength, and Perforated

ASTM C828 (2011) Low-Pressure Air Test of Vitrified

Clay Pipe Lines

ASTM C877 (2008) External Sealing Bands for Concrete

Pipe, Manholes, and Precast Box Sections

ASTM C877M (2002; R 2009) External Sealing Bands for

Concrete Pipe, Manholes, and Precast Box

Sections (Metric)

ASTM C923 (2008; R 2013; E 2016) Standard

Specification for Resilient Connectors

Between Reinforced Concrete Manhole

Structures, Pipes and Laterals

ASTM C923M (2008b; R 2013) Standard Specification for

Resilient Connectors Between Reinforced

Concrete Manhole Structures, Pipes and

Laterals (Metric)

ASTM C969 (2019) Standard Practice for Infiltration and Exfiltration Acceptance Testing of

Installed Precast Concrete Pipe Sewer Lines

ASTM C969M (2019) Standard Practice for Infiltration and Exfiltration Acceptance Testing of

Installed Precast Concrete Pipe Sewer

Lines (Metric)

ASTM C990 (2009; R 2014) Standard Specification for

Joints for Concrete Pipe, Manholes and

Precast Box Sections Using Preformed

Flexible Joint Sealants

ASTM C1103 (2019) Standard Practice for Joint

Acceptance Testing of Installed Precast

Concrete Pipe Sewer Lines

SECTION 33 40 00 Page 6

ASTM C1103M (2019) Standard Practice for Joint

Acceptance Testing of Installed Precast

Concrete Pipe Sewer Lines (Metric)

ASTM C1433 (2016b) Standard Specification for Precast

Reinforced Concrete Monolithic Box

Sections for Culverts, Storm Drains, and

Sewers

ASTM C1433M (2018) Standard Specification for Precast

Reinforced Concrete Monolithic Box

Sections for Culverts, Storm Drains, and

Sewers (Metric)

ASTM D1056 (2014) Standard Specification for Flexible

Cellular Materials - Sponge or Expanded

Rubber

ASTM D1171 (2016; E 2016) Standard Test Method for

Rubber Deterioration - Surface Ozone

Cracking Outdoors (Triangular Specimens)

ASTM D1557 (2012; E 2015) Standard Test Methods for

Laboratory Compaction Characteristics of

Soil Using Modified Effort (56,000 ft-lbf/ft3)

ASTM D1751 (2004; E 2013; R 2013) Standard

Specification for Preformed Expansion

Joint Filler for Concrete Paving and

Structural Construction (Nonextruding and

Resilient Bituminous Types)

ASTM D1752 (2018) Standard Specification for

Preformed Sponge Rubber, Cork and Recycled

PVC Expansion Joint Fillers for Concrete

Paving and Structural Construction

ASTM D1784 (2020) Standard Specification for Rigid

Poly(Vinyl Chloride) (PVC) Compounds and

Chlorinated Poly(Vinyl Chloride) (CPVC)

Compounds

ASTM D2167 (2015) Density and Unit Weight of Soil in

Place by the Rubber Balloon Method

ASTM D2321 (2020) Standard Practice for Underground

Installation of Thermoplastic Pipe for

Sewers and Other Gravity-Flow Applications

ASTM D2729 (2017) Standard Specification for

Poly(Vinyl Chloride) (PVC) Sewer Pipe and

Fittings

ASTM D3034 (2016) Standard Specification for Type PSM

Poly(Vinyl Chloride) (PVC) Sewer Pipe and

Fittings

SECTION 33 40 00 Page 7

ASTM D3212 (2007; R 2020) Standard Specification for

Joints for Drain and Sewer Plastic Pipes

Using Flexible Elastomeric Seals

ASTM D3350 (2012) Polyethylene Plastics Pipe and

Fittings Materials

ASTM D6938 (2017a) Standard Test Method for In-Place

Density and Water Content of Soil and

Soil-Aggregate by Nuclear Methods (Shallow

Depth)

ASTM F477 (2014) Standard Specification for

Elastomeric Seals (Gaskets) for Joining

Plastic Pipe

ASTM F679 (2016) Standard Specification for

Poly(Vinyl Chloride) (PVC) Large-Diameter

Plastic Gravity Sewer Pipe and Fittings

ASTM F714 (2013; R 2019) Standard Specification for

Polyethylene (PE) Plastic Pipe (DR-PR)

Based on Outside Diameter

ASTM F794 (2003; R 2014) Standard Specification for

Poly(Vinyl Chloride) (PVC) Profile Gravity

Sewer Pipe and Fittings Based on

Controlled Inside Diameter

ASTM F894 (2019) Standard Specification for

Polyethylene (PE) Large Diameter Profile

Wall Sewer and Drain Pipe

ASTM F949 (2020) Standard Specification for

Poly(Vinyl Chloride) (PVC) Corrugated

Sewer Pipe with a Smooth Interior and

Fittings

ASTM F1417 (2011a; E 2020) Standard Practice for

Installation Acceptance of Plastic

Non-pressure Sewer Lines Using

Low-Pressure Air

ASTM F2562/F2562M (2015) Specification for Steel Reinforced

Thermoplastic Ribbed Pipe and Fittings for

Non-Pressure Drainage and Sewerage

ASTM F2736 (2013; E 2014) Standard Specification for

6 to 30 in. (152 To 762 mm) Polypropylene

(PP) Corrugated Single Wall Pipe And

Double Wall Pipe

ASTM F2764/F2764M (2018a) Standard Specification for 6 to 60

in. [150 to 1500 mm] Polypropylene (PP)

Corrugated Double and Triple Wall Pipe and

Fittings for Non-Pressure Sanitary Sewer

Applications

ASTM F2881 (2011) Standard Specification for 12 to 60

in. (300 to 1500 mm) Polypropylene (PP)

SECTION 33 40 00 Page 8

Dual Wall Pipe and Fittings for

Non-Pressure Storm Sewer Applications

1.2 SUBMITTALS.

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the government officer that will review the submittal for the Government.

SD-04 Samples

Pipe for Culverts and Storm Drains

SD-07 Certificates

Resin Certification

Oil Resistant Gasket

Leakage Test

Hydrostatic Test on Watertight Joints

Determination of Density

Frame and Cover for Gratings

Post-Installation Inspection Report

SD-08 Manufacturer's Instructions

Placing Pipe

SD-11 Closeout Submittals

Lid Verification Report; G

1.3 DELIVERY, STORAGE, AND HANDLING.

1.3.1 Delivery and Storage

Materials delivered to site shall be inspected for damage, unloaded, and stored with a minimum of handling. Materials shall not be stored directly on the ground. The inside of pipes and fittings shall be kept free of dirt and debris. Before, during, and after installation, plastic fittings shall be protected from any environment that would result in damage or deterioration to the material. Keep a copy of the manufacturer's instructions available at the construction site at all times and follow these instructions unless directed otherwise by the Contracting Officer.

1.3.2 Handling

Materials shall be handled in a manner that ensures delivery to the trench in sound, undamaged condition. Pipe shall be carried to the trench, not dragged.

SECTION 33 40 00 Page 9

PART 2 PRODUCTS.

2.1 PIPE FOR CULVERTS AND STORM DRAINS.

Pipe for culverts and storm drains shall be of the sizes indicated and shall conform to the requirements specified.

2.1.1 Concrete Pipe

Manufactured in accordance with and conforming to ASTM C76M ASTM C76, Class as shown in drawings.

2.1.1.1 Reinforced Arch Culvert and Storm Drainpipe

Manufactured in accordance with and conforming to ASTM C506M ASTM C506,

2.1.1.2 Reinforced Elliptical Culvert and Storm Drainpipe

Manufactured in accordance with and conforming to ASTM C507M ASTM C507.

2.1.1.3 Non-reinforced Pipe

Manufactured in accordance with and conforming to ASTM C14M ASTM C14,

2.1.1.4 Cast-In-Place Non-reinforced Conduit

ACI 346, except that testing shall be the responsibility of and at the expense of the Contractor. In the case of other conflicts between ACI 346 and project specifications, requirements of ACI 346 shall govern.

2.1.2 Precast Reinforced Concrete Box

Manufactured in accordance with and conforming to ASTM C1433M ASTM C1433.

2.2 MISCELLANEOUS MATERIALS.

2.2.1 Concrete

Unless otherwise specified, concrete and reinforced concrete shall conform to the requirements for 3500 psi concrete under Section 03 30 00 CAST-IN-

PLACE CONCRETE. The concrete mixture shall have air content by volume of concrete, based on measurements made immediately after discharge from the mixer, of 5 to 7 percent when maximum size of coarse aggregate exceeds 1-

1/2 inches. Air content shall be determined in accordance with ASTM

C231/C231M. The concrete covering over steel reinforcing shall not be less than 1 inch thick for covers and not less than 1-1/2 inches thick for walls and flooring. Concrete covering deposited directly against the ground shall have a thickness of at least 3 inches between steel and ground. Expansion-joint filler material shall conform to ASTM D1751, or

ASTM D1752, or shall be resin-impregnated fiberboard conforming to the physical requirements of ASTM D1752.

2.2.2 Mortar

Mortar for pipe joints, connections to other drainage structures, and brick or block construction shall conform to ASTM C270, Type M, except that the maximum placement time shall be 1 hour. Water shall be clean and free of harmful acids, alkalis, and organic impurities. The mortar shall be used within 30 minutes after the ingredients are mixed with water. The

SECTION 33 40 00 Page 10 inside of the joint shall be wiped clean and finished smooth. The mortar head on the outside shall be protected from air and sun with a proper covering until satisfactorily cured.

2.2.3 Precast Concrete Segmental Blocks

Precast concrete segmental block shall conform to ASTM C139, not more than

8 inches thick, not less than 8 inches long, and of such shape that joints can be sealed effectively and bonded with cement mortar.

2.2.4 Brick

Brick shall conform to ASTM C62, Grade SW; ASTM C55, Grade S-I or S-II; or

ASTM C32, Grade MS. Mortar for jointing and plastering shall consist of one part Portland cement and two parts fine sand. Lime may be added to the mortar in a quantity not more than 25 percent of the volume of cement.

The joints shall be filled completely and shall be smooth and free from surplus mortar on the inside of the structure. Brick structures shall be plastered with 1/2 inch of mortar over the entire outside surface of the walls. For square or rectangular structures, brick shall be laid in stretcher courses with a header course every sixth course. For round structures, brick shall be laid radially with every sixth course a stretcher course.

2.2.5 Precast Reinforced Concrete Manholes

Conform to ASTM C478M ASTM C478. Joints between precast concrete risers and tops shall be full-bedded in cement mortar and shall be smoothed to a uniform surface on both interior and exterior of the structure made with flexible watertight, rubber-type gaskets meeting the requirements of paragraph JOINTS.

2.2.6 Frame and Cover for Gratings

Submit certification on the ability of frame and cover or gratings to carry the imposed live load. Frame and cover for gratings shall be cast gray iron, ASTM A48/A48M, Class 35B; or cast aluminum, ASTM B26/B26M, Alloy 356.O-T6. Weight, shape, size, and waterway openings for grates and curb inlets shall be as indicated on the plans. The word "Storm Sewer" shall be stamped or cast into covers so that it is plainly visible.

2.2.7 Joints

2.2.7.1 Flexible Watertight Joints

a. Flexible watertight joints shall be made with plastic or rubber-type gaskets for concrete pipe. The design of joints and the physical requirements for preformed flexible joint sealants shall conform to

ASTM C990, and rubber-type gaskets shall conform to ASTM C443M

ASTM C443. Factory-fabricated resilient joint materials shall conform to ASTM C425. Gaskets shall have not more than one factory-fabricated splice, except that two factory-fabricated splices of the rubber-type gasket are permitted if the nominal diameter of the pipe being gasketed exceeds 54 inches.

b. Rubber gaskets shall comply with the oil resistant gasket requirements of ASTM C443M ASTM C443. Certified copies of test results shall be delivered to the Contracting Officer before gaskets or jointing materials are installed. Alternate types of watertight joint may be furnished, if specifically approved.

SECTION 33 40 00 Page 11

2.2.7.2 External Sealing Bands

Requirements for external sealing bands shall conform to ASTM C877M

ASTM C877.

2.2.7.3 Flexible Watertight, Gasketed Joints

a. Gaskets: When infiltration or exfiltration is a concern for pipe lines, the couplings may be required to have gaskets. The closed-cell expanded rubber gaskets shall be a continuous band approximately 7 inches wide and approximately 3/8 inch thick, meeting the requirements of ASTM D1056, Type 2 A1 or B3, and shall have a quality retention rating of not less than 70 percent when tested for weather resistance by ozone chamber exposure, Method B of

ASTM D1171. Rubber O-ring gaskets shall be 13/16 inch in diameter for pipe diameters of 36 inches or smaller and 7/8 inch in diameter for larger pipe having 1/2 inch deep end corrugation. Rubber O-ring gaskets shall be 1-3/8 inches in diameter for pipe having 1 inch deep end corrugations. O-rings shall meet the requirements of ASTM C990 or ASTM C443M

ASTM C443. Preformed flexible joint sealants shall conform to

ASTM C990, Type B.

b. Connecting Bands: Connecting bands shall be of the type, size and sheet thickness of band, and the size of angles, bolts, rods and lugs as indicated or where not indicated as specified in the applicable standards or specifications for the pipe. Exterior rivet heads in the longitudinal seam under the connecting band shall be countersunk or the rivets shall be omitted and the seam welded. Watertight joints shall be tested and shall meet the test requirements of paragraph

HYDROSTATIC TEST ON WATERTIGHT JOINTS.

2.3 STEEL LADDER.

Steel ladder shall be provided where the depth of the storm drainage structure exceeds 12 feet. These ladders shall be not less than 16 inches in width, with 3/4 inch diameter rungs spaced 12 inches apart.

The two stringers shall be a minimum 3/8 inch thick and 2-1/2 inches wide. Ladders and inserts shall be galvanized after fabrication in conformance with ASTM A123/A123M.

2.4 RESILIENT CONNECTORS.

Flexible, watertight connectors used for connecting pipe to manholes and inlets shall conform to ASTM C923M ASTM C923.

2.5 EROSION CONTROL RIP RAP.

Provide non-erodible rock not exceeding 15 inches in its greatest dimension and choked with sufficient small rocks to provide a dense mass with a minimum thickness of as indicated.

PART 3 EXECUTION.

3.1 INSTALLATION OF PIPE CULVERTS, STORM DRAINS, AND DRAINAGE STRUCTURES.

SECTION 33 40 00 Page 12

Excavation of trenches, and for appurtenances and backfilling for culverts and storm drains, shall be in accordance with the applicable portions of

Section 31 00 00 EARTHWORK and the requirements specified below.

3.1.1 Trenching

The width of trenches at any point below the top of the pipe shall be not greater than the outside diameter of the pipe plus 16 inches to permit satisfactory jointing and thorough tamping of the bedding material under and around the pipe. Sheeting and bracing, where required, shall be placed within the trench width as specified, without any over excavation.

Where trench widths are exceeded, redesign with a resultant increase in cost of stronger pipe or special installation procedures will be necessary. Cost of this redesign and increased cost of pipe or installation shall be borne by the Contractor without additional cost to the Government.

3.1.2 Removal of Rock

Rock in either ledge or boulder formation shall be replaced with suitable materials to provide a compacted earth cushion having a thickness between unremoved rock and the pipe of at least 8 inches or 1/2 inch for each foot of fill over the top of the pipe, whichever is greater, but not more than three-fourths the nominal diameter of the pipe. Where bell-and-spigot pipe is used, the cushion shall be maintained under the bell as well as under the straight portion of the pipe. Rock excavation shall be as specified and defined in Section 31 00 00 EARTHWORK.

3.1.3 Removal of Unstable Material

Where wet or otherwise unstable soil incapable of properly supporting the pipe, as determined by the Contracting Officer, is unexpectedly encountered in the bottom of a trench, such material shall be removed to the depth required and replaced to the proper grade with select granular material, compacted as provided in paragraph BACKFILLING. When removal of unstable material is due to the fault or neglect of the Contractor while performing shoring and sheeting, water removal, or other specified requirements, such removal and replacement shall be performed at no additional cost to the Government.

3.2 BEDDING.

The bedding surface for the pipe shall provide a firm foundation of uniform density throughout the entire length of the pipe.

3.2.1 Concrete Pipe Requirements

When no bedding class is specified or detailed on the drawings, concrete pipe shall be bedded in granular material minimum 4 inch in depth in trenches with soil foundation. Depth of granular bedding in trenches with rock foundation shall be 1/2 inch in depth per foot of depth of fill, minimum depth of bedding shall be 8 inch up to maximum depth of 24 inches.

The middle third of the granular bedding shall be loosely placed. Bell holes and depressions for joints shall be removed and formed so entire barrel of pipe is uniformly supported. The bell hole and depressions for the joints shall be not more than the length, depth, and width required for properly making the particular type of joint.

3.3 PLACING PIPE.

Each pipe shall be thoroughly examined before being laid; defective or

SECTION 33 40 00 Page 13 damaged pipe shall not be used. Pipelines shall be laid to the grades and alignment indicated. Proper facilities shall be provided for lowering sections of pipe into trenches. Lifting lugs in vertically elongated pipe shall be placed in the same vertical plane as the major axis of the pipe.

Pipe shall not be laid in water, and pipe shall not be laid when trench conditions or weather are unsuitable for such work. Diversion of drainage or dewatering of trenches during construction shall be provided as necessary. Deflection of installed flexible pipe shall not exceed the following limits:

TYPE OF PIPE MAXIMUM ALLOWABLE

DEFLECTION (percent)

Concrete-Lined Corrugated Steel 3

Note post installation requirements of paragraph DEFLECTION TESTING in

PART 3 of this specification for all pipe products including deflection testing requirements for flexible pipe.

3.3.1 Concrete

Laying shall proceed upgrade with spigot ends of bell-and-spigot pipe and tongue ends of tongue-and-groove pipe pointing in the direction of the flow.

3.3.2 Elliptical and Elliptical Reinforced Concrete Pipe

The manufacturer's reference lines, designating the top of the pipe, shall be within 5 degrees of a vertical plane through the longitudinal axis of the pipe, during placement. Damage to or misalignment of the pipe shall be prevented in all backfilling operations.

3.3.3 Corrugated Steel and Aluminum Pipe and Pipe Arch

Laying shall be with the separate sections joined firmly together, with the outside laps of circumferential joints pointing upstream, and with longitudinal laps on the sides. Part paved pipe shall be installed so that the centerline of bituminous pavement in the pipe, indicated by suitable markings on the top at each end of the pipe sections, coincides with the specified alignment of pipe. Fully paved steel pipe or pipe arch shall have a painted or otherwise applied label inside the pipe or pipe arch indicating sheet thickness of pipe or pipe arch. Any unprotected metal in the joints shall be coated with bituminous material as specified in AASHTO M 190 or AASHTO M 243. Interior coating shall be protected against damage from insertion or removal of struts or tie wires. Lifting lugs shall be used to facilitate moving pipe without damage to exterior or interior coatings. During transportation and installation, pipe or pipe arch and coupling bands shall be handled with care to preclude damage to the coating, paving or lining. Damaged coatings, pavings and linings shall be repaired in accordance with the manufacturer's recommendations prior to placing backfill. Pipe on which coating, paving or lining has been damaged to such an extent that satisfactory field repairs cannot be made shall be removed and replaced. Vertical elongation, where indicated, shall be accomplished by factory elongation. Suitable markings or properly placed lifting lugs shall be provided to ensure placement of factory elongated pipe in a vertical plane.

3.3.4 Structural-Plate Steel

Structural plate shall be installed in accordance with ASTM A807/A807M.

Structural plate shall be assembled in accordance with instructions

SECTION 33 40 00 Page 14 furnished by the manufacturer. Instructions shall show the position of each plate and the order of assembly. Bolts shall be tightened progressively and uniformly, starting at one end of the structure after all plates are in place. The operation shall be repeated to ensure that all bolts are tightened to meet the torque requirements of 200 foot-pounds plus or minus 50 foot-pounds. Any power wrenches used shall be checked by the use of hand torque wrenches or long-handled socket or structural wrenches for amount of torque produced. Power wrenches shall be checked and adjusted frequently as needed, according to type or condition, to ensure proper adjustment to supply the required torque.

3.3.5 Structural-Plate Aluminum

Structural plate shall be assembled in accordance with instructions furnished by the manufacturer. Instructions shall show the position of each plate and the order of assembly. Bolts shall be tightened progressively and uniformly, starting at one end of the structure after all plates are in place. The operation shall be repeated to ensure that all bolts are torqued to a minimum of 100 foot-pounds on aluminum alloy bolts and a minimum of 150 foot-pounds on galvanized steel bolts. Any power wrenches used shall be checked by the use of hand torque wrenches or long-handled socket or structural wrenches for the amount of torque produced. Power wrenches shall be checked and adjusted as frequently as needed, according to type or condition, to ensure that they are in proper adjustment to supply the required torque.

3.3.6 Multiple Culverts

Where multiple lines of pipe are installed, adjacent sides of pipe shall be at least half the nominal pipe diameter or 3 feet apart, whichever is less.

3.4 JOINTING.

3.4.1 Concrete

3.4.1.1 Cement-Mortar Bell-and-Spigot Joint

The first pipe shall be bedded to the established grade line, with the bell end placed upstream. The interior surface of the bell shall be thoroughly cleaned with a wet brush and the lower portion of the bell filled with mortar as required to bring inner surfaces of abutting pipes flush and even. The spigot end of each subsequent pipe shall be cleaned with a wet brush and uniformly matched into a bell so that sections are closely fitted. After each section is laid, the remainder of the joint shall be filled with mortar, and a bead shall be formed around the outside of the joint with sufficient additional mortar. If mortar is not sufficiently stiff to prevent appreciable slump before setting, the outside of the joint shall be wrapped or bandaged with cheesecloth to hold mortar in place.

3.4.1.2 Cement-Mortar Oakum Joint for Bell-and-Spigot Pipe

A closely twisted gasket shall be made of jute or oakum of the diameter required to support the spigot end of the pipe at the proper grade and to make the joint concentric. Joint packing shall be in one piece of sufficient length to pass around the pipe and lap at top. This gasket shall be thoroughly saturated with neat cement grout. The bell of the pipe shall be thoroughly cleaned with a wet brush, and the gasket shall be laid in the bell for the lower third of the circumference and covered with mortar. The spigot of the pipe shall be thoroughly cleaned with a wet

SECTION 33 40 00 Page 15 brush, inserted in the bell, and carefully driven home. A small amount of mortar shall be inserted in the annular space for the upper two-thirds of the circumference. The gasket shall be lapped at the top of the pipe and driven home in the annular space with a caulking tool. The remainder of the annular space shall be filled completely with mortar and beveled at an angle of approximately 45 degrees with the outside of the bell. If mortar is not sufficiently stiff to prevent appreciable slump before setting, the outside of the joint thus made shall be wrapped with cheesecloth. Placing of this type of joint shall be kept at least five joints behind laying operations.

3.4.1.3 Cement-Mortar Diaper Joint for Bell-and-Spigot Pipe

The pipe shall be centered so that the annular space is uniform. The annular space shall be caulked with jute or oakum. Before caulking, the inside of the bell and the outside of the spigot shall be cleaned.

3.4.1.3.1. Diaper Bands:

Diaper bands shall consist of heavy cloth fabric to hold grout in place at joints and shall be cut in lengths that extend one-eighth of the circumference of pipe above the spring line on one side of the pipe and up to the spring line on the other side of the pipe.

Longitudinal edges of fabric bands shall be rolled and stitched around two pieces of wire. Width of fabric bands shall be such that after fabric has been securely stitched around both edges on wires, the wires will be uniformly spaced not less than 8 inches apart.

Wires shall be cut into lengths to pass around pipe with sufficient extra length for the ends to be twisted at top of pipe to hold the band securely in place; bands shall be accurately centered around lower portion of joint.

3.4.1.3.2. Grout:

Grout shall be poured between band and pipe from the high side of band only, until grout rises to the top of band at the spring line of pipe, or as nearly so as possible, on the opposite side of pipe, to ensure a thorough sealing of joint around the portion of pipe covered by the band. Silt, slush, water, or polluted mortar grout forced up on the lower side shall be forced out by pouring, and removed.

3.4.1.3.3. Remainder of Joint:

3.4.1.3.4. The remaining unfilled upper portion of the joint shall be filled with mortar and a bead formed around the outside of this upper portion of the joint with a sufficient amount of additional mortar. The diaper shall be left in place. Placing of this type of joint shall be kept at least five joints behind actual laying of pipe. No backfilling around joints shall be done until joints have been fully inspected and approved.

3.4.1.4 Cement-Mortar Tongue-and-Groove Joint

The first pipe shall be bedded carefully to the established grade line with the groove upstream. A shallow excavation shall be made underneath the pipe at the joint and filled with mortar to provide a bed for the pipe. The grooved end of the first pipe shall be thoroughly cleaned with a wet brush, and a layer of soft mortar applied to the lower half of the groove. The tongue of the second pipe shall be cleaned with a wet brush;

while in horizontal position, a layer of soft mortar shall be applied to

SECTION 33 40 00 Page 16 the upper half of the tongue. The tongue end of the second pipe shall be inserted in the grooved end of the first pipe until mortar is squeezed out on interior and exterior surfaces. Sufficient mortar shall be used to fill the joint completely and to form a bead on the outside.

3.4.1.5 Cement-Mortar Diaper Joint for Tongue-and-Groove Pipe

The joint shall be of the type described for cement-mortar tongue-and-groove joint in this paragraph, except that the shallow excavation directly beneath the joint shall not be filled with mortar until after a gauze or cheesecloth band dipped in cement mortar has been wrapped around the outside of the joint. The cement-mortar bead at the joint shall be at least 1/2 inch, thick and the width of the diaper band shall be at least 8 inches. The diaper shall be left in place. Placing of this type of joint shall be kept at least five joints behind the actual laying of the pipe. Backfilling around the joints shall not be done until the joints have been fully inspected and approved.

3.4.1.6 Plastic Sealing Compound Joints for Tongue-and-Grooved Pipe

Sealing compounds shall follow the recommendation of the particular manufacturer in regard to special installation requirements. Surfaces to receive lubricants, primers, or adhesives shall be dry and clean. Sealing compounds shall be affixed to the pipe not more than 3 hours prior to installation of the pipe, and shall be protected from the sun, blowing dust, and other deleterious agents at all times. Sealing compounds shall be inspected before installation of the pipe, and any loose or improperly affixed sealing compound shall be removed and replaced. The pipe shall be aligned with the previously installed pipe, and the joint pulled together.

If, while making the joint with mastic-type sealant, a slight protrusion of the material is not visible along the entire inner and outer circumference of the joint when the joint is pulled up, the pipe shall be removed and the joint remade. After the joint is made, all inner protrusions shall be cut off flush with the inner surface of the pipe. If non-mastic-type sealant material is used, the "Squeeze-Out" requirement above will be waived.

3.4.1.7 Flexible Watertight Joints

Gaskets and jointing materials shall be as recommended by the particular manufacturer in regard to use of lubricants, cements, adhesives, and other special installation requirements. Surfaces to receive lubricants, cements, or adhesives shall be clean and dry. Gaskets and jointing materials shall be affixed to the pipe not more than 24 hours prior to the installation of the pipe, and shall be protected from the sun, blowing dust, and other deleterious agents at all times. Gaskets and jointing materials shall be inspected before installing the pipe; any loose or improperly affixed gaskets and jointing materials shall be removed and replaced. The pipe shall be aligned with the previously installed pipe, and the joint pushed home. If, while the joint is being made the gasket becomes visibly dislocated the pipe shall be removed and the joint remade.

3.4.1.8 External Sealing Band Joint for Noncircular Pipe

Surfaces to receive sealing bands shall be dry and clean. Bands shall be installed in accordance with manufacturer's recommendations.

3.4.2 Corrugated Steel and Aluminum Pipe

3.4.2.1 Field Joints

SECTION 33 40 00 Page 17

Transverse field joints shall be designed so that the successive connection of pipe sections will form a continuous line free of appreciable irregularities in the flow line. In addition, the joints shall meet the general performance requirements described in

ASTM A798/A798M. Suitable transverse field joints which satisfy the requirements for one or more of the joint performance categories can be obtained with the following types of connecting bands furnished with suitable band-end fastening devices: corrugated bands, bands with projections, flat bands, and bands of special design that engage factory reformed ends of corrugated pipe. The space between the pipe and connecting bands shall be kept free from dirt and grit so that corrugations fit snugly. The connecting band, while being tightened, shall be tapped with a soft-head mallet of wood, rubber or plastic, to take up slack and ensure a tight joint. [The annular space between abutting sections of part paved, and fully paved pipe and pipe arch, in sizes 30 inches or larger, shall be filled with a bituminous material after jointing.] Field joints for each type of corrugated metal pipe shall maintain pipe alignment during construction and prevent infiltration of fill material during the life of the installations. The type, size, and sheet thickness of the band and the size of angles or lugs and bolts shall be as indicated or where not indicated, shall be as specified in the applicable standards or specifications for the pipe.

3.4.2.2 Flexible Watertight, Gasketed Joints

Installation shall be as recommended by the gasket manufacturer for use of lubricants and cements and other special installation requirements. The gasket shall be placed over one end of a section of pipe for half the width of the gasket. The other half shall be doubled over the end of the same pipe. When the adjoining section of pipe is in place, the doubled-over half of the gasket shall then be rolled over the adjoining section. Any unevenness in overlap shall be corrected so that the gasket covers the end of pipe sections equally. Connecting bands shall be centered over adjoining sections of pipe, and rods or bolts placed in position and nuts tightened. Band Tightening: The band shall be tightened evenly, even tension being kept on the rods or bolts, and the gasket; the gasket shall seat properly in the corrugations. Watertight joints shall remain uncovered for a period of time designated, and before being covered, tightness of the nuts shall be measured with a torque wrench. If the nut has tended to loosen its grip on the bolts or rods, the nut shall be retightened with a torque wrench and remain uncovered until a tight, permanent joint is assured.

3.5 DRAINAGE STRUCTURES.

As specified in Drawings.

3.5.1 Manholes and Inlets

Construction shall be of reinforced concrete, plain concrete, brick, precast reinforced concrete, precast concrete segmental blocks, prefabricated corrugated metal, or bituminous coated corrugated metal;

complete with frames and covers or gratings; and with fixed galvanized steel ladders where indicated. Pipe studs and junction chambers of prefabricated corrugated metal manholes shall be fully bituminous-coated and paved when the connecting branch lines are so treated. Pipe connections to concrete manholes and inlets shall be made with flexible, watertight connectors.

3.5.2 Walls and Headwalls

SECTION 33 40 00 Page 18

Construction shall be as indicated in drawings.

3.6 STEEL LADDER INSTALLATION.

Ladder shall be adequately anchored to the wall by means of steel inserts spaced not more than 6 feet vertically, and shall be installed to provide at least 6 inches of space between the wall and the rungs. The wall along the line of the ladder shall be vertical for its entire length.

3.7 BACKFILLING.

3.7.1 Backfilling Pipe in Trenches

After the pipe has been properly bedded, selected material from excavation or borrow, at a moisture content that will facilitate compaction, shall be placed along both sides of pipe in layers not exceeding 6 inches in compacted depth. The backfill shall be brought up evenly on both sides of pipe for the full length of pipe. The fill shall be thoroughly compacted under the haunches of the pipe. Each layer shall be thoroughly compacted with mechanical tampers or rammers. This method of filling and compacting shall continue until the fill has reached an elevation equal to the midpoint (spring line) of concrete pipe or has reached an elevation of at least 12 inches above the top of the pipe for flexible pipe. The remainder of the trench shall be backfilled and compacted by spreading and rolling or compacted by mechanical rammers or tampers in layers not exceeding 6 inches. Tests for density shall be made as necessary to ensure conformance to the compaction requirements specified below. Where it is necessary, in the opinion of the Contracting Officer, that sheeting or portions of bracing used be left in place, the contract will be adjusted accordingly.

Untreated sheeting shall not be left in place beneath structures or pavements.

3.7.2 Backfilling Pipe in Fill Sections

For pipe placed in fill sections, backfill material and the placement and compaction procedures shall be as specified below. The fill material shall be uniformly spread in layers longitudinally on both sides of the pipe, not exceeding 6 inches in compacted depth, and shall be compacted by rolling parallel with pipe or by mechanical tamping or ramming. Prior to commencing normal filling operations, the crown width of the fill at a height of 12 inches above the top of the pipe shall extend a distance of not less than twice the outside pipe diameter on each side of the pipe or

12 feet, whichever is less. After the backfill has reached at least 12 inches above the top of the pipe, the remainder of the fill shall be placed and thoroughly compacted in layers not exceeding 6 inches. Use select granular material for this entire region of backfill for flexible pipe installations.

3.7.3 Movement of Construction Machinery

When compacting by rolling or operating heavy equipment parallel with the pipe, displacement of or injury to the pipe shall be avoided. Movement of construction machinery over a culvert or storm drain at any stage of construction shall be at the Contractor's risk. Any damaged pipe shall be repaired or replaced.

3.7.4 Compaction

3.7.4.1 General Requirements

SECTION 33 40 00 Page 19

Cohesionless materials include gravels, gravel-sand mixtures, sands, and gravelly sands. Cohesive materials include clayey and silty gravels, gravel-silt mixtures, clayey and silty sands, sand-clay mixtures, clays, silts, and very fine sands. When results of compaction tests for moisture-density relations are recorded on graphs, cohesionless soils will show straight lines or reverse-shaped moisture-density curves, and cohesive soils will show normal moisture-density curves.

3.7.4.2 Minimum Density

Backfill over and around the pipe and backfill around and adjacent to drainage structures shall be compacted at the approved moisture content to the following applicable minimum density, which will be determined as specified below.

3.7.4.2.1. Under airfield and heliport pavements, paved roads, streets, parking areas, and similar-use pavements including adjacent shoulder areas, the density shall be not less than 90 percent of maximum density for cohesive material and 95 percent of maximum density for cohesionless material, up to the elevation where requirements for pavement subgrade materials and compaction shall control.

3.7.4.2.2. Under unpaved or turfed traffic areas, density shall not be less than 90 percent of maximum density for cohesive material and 95 percent of maximum density for cohesionless material.

3.7.4.2.3. Under nontraffic areas, density shall be not less than that of the surrounding material.

3.8 FIELD PAINTING.

3.8.1 Cast-Iron Covers, Frames, Gratings, And Steps

After installation, clean cast-iron, not buried in masonry or concrete, of mortar, rust, grease, dirt, and other deleterious materials to bare metal and apply a coat of bituminous paint.

3.8.2 Steel Covers And Frames Or Concrete Frames

After installation, clean steel or concrete, not buried in masonry or concrete, of mortar, dirt, grease, and other deleterious materials to bare metal.

3.9 FIELD QUALITY CONTROL.

3.9.1 Tests

Testing is the responsibility of the Contractor. Perform all testing and retesting at no additional cost to the Government.

3.9.1.1 HYDROSTATIC TEST ON WATERTIGHT JOINTS

Watertight joints shall be tested and shall meet test requirements of paragraph HYDROSTATIC TEST ON WATERTIGHT JOINTS. Rubber gaskets shall comply with the oil resistant gasket requirements of ASTM C443M ASTM C443.

Certified copies of test results shall be delivered to the Contracting

Officer before gaskets or jointing materials are installed.

3.9.1.1.1 Concrete

SECTION 33 40 00 Page 20

A hydrostatic test shall be made on the watertight joint types as proposed. Only one sample joint of each type needs testing; however, if the sample joint fails because of faulty design or workmanship, an additional sample joint may be tested. During the test period, gaskets or other jointing material shall be protected from extreme temperatures which might adversely affect the performance of such materials. Performance requirements for joints in reinforced and nonreinforced concrete pipe shall conform to ASTM C990 or ASTM C443M ASTM C443.

3.9.1.2 Leakage Test

Lines shall be tested for leakage by low pressure air or water testing or exfiltration tests, as appropriate, prior to completing backfill. Low pressure air testing for concrete pipes shall conform to ASTM C969M ASTM

C969. Low pressure air testing procedures for other pipe materials shall use the pressures and testing times prescribed in ASTM C828 or ASTM C969M

ASTM C969, after consultation with the pipe manufacturer. Testing of individual joints for leakage by low pressure air or water shall conform to ASTM C1103M ASTM C1103. Prior to exfiltration tests, the trench shall be backfilled up to at least the lower half of the pipe. If required, sufficient additional backfill shall be placed to prevent pipe movement during testing, leaving the joints uncovered to permit inspection.

Visible leaks encountered shall be corrected regardless of leakage test results. When the water table is 2 feet or more above the top of the pipe at the upper end of the pipeline section to be tested, infiltration shall be measured using a suitable weir or other device acceptable to the

Contracting Officer. An exfiltration test shall be made by filling the line to be tested with water so that a head of at least 2 feet is provided above both the water table and the top of the pipe at the upper end of the pipeline to be tested. The filled line shall be allowed to stand until the pipe has reached its maximum absorption, but not less than 4 hours. After absorption, the head shall be reestablished. The amount of water required to maintain this water level during a 2-hour test period shall be measured. Leakage as measured by the exfiltration test shall not exceed 250 gallons per inch in diameter per mile of pipeline per day 0.2 gallons per inch in diameter per 100 feet of pipeline per hour.

3.9.1.3 Determination of Density

Testing shall be performed by an approved commercial testing laboratory or by the Contractor subject to approval. Tests shall be performed in sufficient number to ensure that specified density is being obtained.

Laboratory tests for moisture-density relations shall be made in accordance with ASTM D1557 except that mechanical tampers may be used provided the results are correlated with those obtained with the specified hand tamper. Field density tests shall be determined in accordance with

ASTM D2167 or ASTM D6938. When ASTM D6938 is used, the calibration curves shall be checked and adjusted, if necessary, using the sand cone method as described in paragraph Calibration of the referenced publications.

ASTM D6938 results in a wet unit weight of soil and ASTM D6938 shall be used to determine the moisture content of the soil. The calibration curves furnished with the moisture gauges shall be checked along with density calibration checks as described in ASTM D6938. Test results shall be furnished the Contracting Officer. The calibration checks of both the density and moisture gauges shall be made at the beginning of a job on each different type of material encountered and at intervals as directed.

3.9.1.4 Deflection Testing

SECTION 33 40 00 Page 21

Conduct deflection test no sooner than 30 days after completion of final backfill and compaction testing. Clean or flush all lines prior to testing. Perform a deflection test on entire length of installed flexible pipeline upon completion of work adjacent to and over the pipeline, including backfilling, placement of fill, grading, paving, placement of concrete, and any other superimposed loads. Deflection of pipe in the installed pipeline under external loads shall not exceed limits in paragraph PLACING PIPE above as percent of the average inside diameter of pipe. Use a mandrel to determine if allowable deflection has been exceeded.

3.9.1.4.1. Laser Profiler

Inspect pipe interior with laser profiling equipment. Utilize low barrel distortion video equipment for pipe sizes 48 inches or less. Use a camera with suitable lighting to allow a clear picture of the entire periphery of the pipe interior. Center the camera in the pipe both vertically and horizontally. The camera must be able to pan and tilt to a 90 degree angle with the axis of the pipe rotating 360 degrees. Use equipment to move the camera through the pipe that will not obstruct the camera's view or interfere with proper documentation of the pipe's condition. The video image shall be clear, focused, and relatively free from roll static or other image distortion qualities that would prevent the reviewer from evaluating the condition of the pipe. For initial post installation inspections for pipe sizes larger than 48 inches, a visual inspection shall be completed of the pipe interior.

3.9.1.4.2. Mandrel

Pass the mandrel through each run of pipe by pulling it by hand. If deflection readings in excess of the allowable deflection of average inside diameter of pipe are obtained, stop and begin test from…