C04 Merged Specs 1240LT26Q0126.docx

USDA FOREST SERVICE, R4

Upper Baker Site Development

SECTION 011900 - MOBILIZATION

GENERAL

SUMMARY

This item is intended to compensate the Contractor for operations including, but not limited to, those necessary for the movement of personnel, equipment, supplies, and incidentals to the project site; for payment of premiums for bonds and insurance for the project; and for any other work and operations which must be performed or costs that must be incurred incident to the initiation of meaningful work at the site and for which payment is not otherwise provided for under the contract.

MEASUREMENT AND PAYMENT

The measurement shall be lump sum for mobilization. Payment shall be as follows:

Bond premiums will be reimbursed after receipt of the evidence of payment.

50% of the lump sum, not to exceed 5% of the original contract amount, will be paid following completion of 5% of the original contract amount not including mobilization and bond premiums.

Payment of the remaining portion of the lump sum, up to 10% of the original contract amount, will be paid following completion of 10% of the original contract amount not including mobilization and bond premiums.

Any portion of the lump sum in excess of 10% of the original contract amount will be paid after final acceptance.

Progress payments for mobilization and preparatory work shall be subject to retainage.

PRODUCTS (NOT USED)

EXECUTION (NOT USED)

END OF SECTION 011900

June 2026

MOBILIZATION 011900-1

USDA FOREST SERVICE, R4

Upper Baker Site Development

SECTION 024100 - WASTE MATERIAL DISPOSAL

1. GENERAL

SUMMARY

This Section includes the loading, handling, hauling, and placing of excess excavation material, unsuitable excavation material, clearing and grubbing debris, and construction and demolition debris.

MEASUREMENT AND PAYMENT

There will be no separate measurement or payment for work in this Section. Waste material disposal is considered incidental to other items of work shown in the Schedule of Items.

PRODUCTS – NOT APPLICABLE

EXECUTION

WASTE MATERIAL TO BE HAULED TO A DISPOSAL AREA

All excavated material not used in the construction of embankments or backfilling of trenches, or other excess material resulting from the excavation and embankment operation shall be hauled to a disposal area.

All unsuitable excavated material and oversize boulders shall be hauled to a disposal area.

[All stumps, slash and other clearing and grubbing debris shall be hauled to a disposal area.] Disposal Area: All waste material above shall be hauled to the disposal area on Government property [as indicated on the Drawings.][as designated by the Contracting Officer.] Waste material shall be piled and compacted to form a dense layer.

The size and shape of the piled waste material shall be designated by the Contracting Officer.

The piled material shall be covered with soil to a uniform depth of six inches minimum and sloped to 2:1 or flatter.

The disposal site shall be left suitable for seeding.

WASTE MATERIAL TO BE HAULED TO A LANDFILL

All demolition materials, garbage, and other refuse generated shall be removed from the project site and legally disposed off of Government property in an approved landfill.

The contractor is responsible for all costs and permits associated with landfill disposal.

The Government is not responsible for waste material upon its departure from the project site.

END OF SECTION 024100

XXX 0000

WASTE MATERIAL DISPOSAL 024100-2

Upper Baker Site Development

SECTION 033000 - CAST-IN-PLACE CONCRETE

1. GENERAL

SUMMARY

This Section specifies cast-in place concrete, including formwork, reinforcement, concrete materials, mixture design, placement procedures, and finishes.

DEFINITIONS

Cementitious Materials: Portland cement alone or in combination with one or more of the following: blended hydraulic cement, fly ash and other pozzolans, ground granulated blast-furnace slag, and silica fume; subject to compliance with requirements.

SUBMITTALS

Product Data: For each type of product indicated.

Design Mixtures: For each concrete mixture. Indicate amounts of mixing water to be withheld for later addition at Project site.

Steel Reinforcement Shop Drawings when project design requires special consideration.

Field quality-control test reports.

MEASUREMENT AND PAYMENT

There will be no separate measurement or payment for work in this section. Payment will be included at the contract unit price for items shown on the Schedule of Items.

PRODUCTS

FORM-FACING MATERIALS

Smooth-Formed Finished Concrete: Form-facing panels that will provide continuous, true, and smooth concrete surfaces. Furnish in largest practicable sizes to minimize number of joints.

Plywood, metal, or other approved panel materials.

Exterior-grade plywood panels, suitable for concrete forms, complying with DOC PS 1, and as follows:

Structural 1, B-B or better; mill oiled and edge sealed.

B-B (Concrete Form), Class 1 or better; mill oiled and edge sealed.

Rough-Formed Finished Concrete: Plywood, lumber, metal, or another approved material. Provide lumber dressed on at least two edges and one side for tight fit.

Forms for Cylindrical Columns, Pedestals, and Supports: Metal, glass-fiber-reinforced plastic, paper, or fiber tubes that will produce surfaces with gradual or abrupt irregularities not exceeding specified formwork surface class. Provide units with sufficient wall thickness to resist plastic concrete loads without detrimental deformation.

Form-Release Agent: Commercially formulated form-release agent that will not bond with, stain, or adversely affect concrete surfaces and will not impair subsequent treatments of concrete surfaces.

Form Ties: Factory-fabricated, removable or snap-off metal or glass-fiber-reinforced plastic form ties designed to resist lateral pressure of fresh concrete on forms and to prevent spalling of concrete on removal.

STEEL REINFORCEMENT

Reinforcing Bars: ASTM A 615/A 615M, Grade 60 , deformed.

Plain-Steel Wire: ASTM A 82, as drawn.

Deformed-Steel Wire: ASTM A 496.

REINFORCEMENT ACCESSORIES

Joint Dowel Bars: ASTM A 615/A 615M, Grade 60, plain-steel bars, cut bars true to length with ends square and free of burrs.XXX 0000 Bar Supports: Bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening reinforcing bars and welded wire reinforcement in place. Manufacture bar supports from steel wire, plastic, or precast concrete according to CRSI's "Manual of Standard Practice," of greater compressive strength than concrete and as follows:

For concrete surfaces exposed to view where legs of wire bar supports contact forms, use CRSI Class 1 plastic-protected steel wire or CRSI Class 2 stainless-steel bar supports.

CONCRETE MATERIALS

Cementitious Material: Use the following cementitious materials, of the same type, brand, and source, throughout Project:

Portland Cement: ASTM C 150, Type II.

Normal-Weight Aggregates: ASTM C 33, graded, from a single source.

Maximum Coarse-Aggregate Size: 1 inch (25 mm) nominal.

Fine Aggregate: Free of materials with deleterious reactivity to alkali in cement.

Water: ASTM C 94/C 94M and potable.

Fly ash, ground iron blast-furnace slag, or silica fume may partially replace cement in any mix as follows:

Fly Ash:

Class F – Not more than 20 percent of the minimum mass of portland cement may be replaced with class F fly ash.

Class C – Not more than 25 percent of the minimum mass of portland cement may be replaced with class C fly ash.

Ground Iron Blast-Furnace Slag: Not more than 25 percent of the minimum mass of portland cement may be replaced with ground iron blast-furnace slag.

Silica Fume (microsilica): Not more than 10 percent of the minimum mass of portland cement may be replaced with silica fume.

Additionally, fly ash, slag, and silica fume will constitute no more than 50 percent of the total replacement weight.

ADMIXTURES

Air-Entraining Admixture: ASTM C 260.

Chemical Admixtures: Provide admixtures certified by manufacturer to be compatible with other admixtures and that will not contribute water-soluble chloride ions exceeding those permitted in hardened concrete. Do not use calcium chloride or admixtures containing calcium chloride.

Retarding Admixture: ASTM C 494/C 494M, Type B.

Synthetic Fiber: Monofilament or fibrillated polypropylene fibers engineered and designed for use in concrete pavement, complying with ASTM C 1116, Type III, 1/2 to 1-1/2 inches long.

VAPOR RETARDERS

Plastic Vapor Retarder: ASTM E 1745, Class C, or polyethylene sheet, ASTM D 4397, not less than 10 mils (0.25 mm) thick. Include manufacturer's recommended adhesive or pressure-sensitive joint tape.

CURING MATERIALS

Absorptive Cover: AASHTO M 182, Class 2, burlap cloth made from jute or kenaf, weighing approximately 9 oz./sq. yd. when dry.

Moisture-Retaining Cover: ASTM C 171, polyethylene film or white burlap-polyethylene sheet.

Water: Potable.

CONCRETE MIXTURES, GENERAL

Prepare design mixtures for each type and strength of concrete, proportioned on the basis of laboratory trial mixture or field test data, or both, according to ACI 301.

Use a qualified independent testing agency for preparing and reporting proposed mixture designs based on laboratory trial mixtures.

CONCRETE MIXTURES FOR BUILDING ELEMENTS

Slabs-on-Grade: Proportion normal-weight concrete mixture as follows:

Minimum Compressive Strength: 3500 psi (24.1 MPa) at 28 days.

Minimum Cementitious Materials Content: 540 lb/cu. yd. (320 kg/cu. m).

Slump Limit: 4 inches (100 mm), plus or minus 1 inch (25 mm).

Air Content: 5 percent, plus or minus 1 percent at point of delivery for 1-inch (25-mm) nominal maximum aggregate size.

Air Content: Do not allow air content of troweled finished floors to exceed 3 percent.

FABRICATING REINFORCEMENT

Fabricate steel reinforcement according to CRSI's "Manual of Standard Practice."

CONCRETE MIXING

Ready-Mixed Concrete: Measure, batch, mix, and deliver concrete according to ASTM C 94/C 94M and ASTM C 1116, and furnish batch ticket information.

When air temperature is between 85 and 90 deg F (30 and 32 deg C), reduce mixing and delivery time from 1-1/2 hours to 75 minutes; when air temperature is above 90 deg F (32 deg C), reduce mixing and delivery time to 60 minutes.

Project-Site Mixing: Measure, batch, and mix concrete materials and concrete according to ASTM C 94/C 94M. Mix concrete materials in appropriate drum-type batch machine mixer.

For mixer capacity of 1 cu. yd. (0.76 cu. m) or smaller, continue mixing at least 1-1/2 minutes, but not more than 5 minutes after ingredients are in mixer, before any part of batch is released.

For mixer capacity larger than 1 cu. yd. (0.76 cu. m), increase mixing time by 15 seconds for each additional 1 cu. yd. (0.76 cu. m).

Provide batch ticket for each batch discharged and used in the Work, indicating Project identification name and number, date, mixture type, mixture time, quantity, and amount of water added. Record approximate location of final deposit in structure.

EXECUTION

FORMWORK

Design, erect, shore, brace, and maintain formwork, according to ACI 301, to support vertical, lateral, static, and dynamic loads, and construction loads that might be applied, until structure can support such loads.

Construct formwork so concrete members and structures are of size, shape, alignment, elevation, and position indicated, within tolerance limits of ACI 117.

Limit concrete surface irregularities, designated by ACI 347R as abrupt or gradual, as follows:

Class A, 1/8 inch (3.2 mm) for smooth-formed finished surfaces.

Class B, 1/4 inch (6 mm) for rough-formed finished surfaces.

Construct forms tight enough to prevent loss of concrete mortar.

Fabricate forms for easy removal without hammering or prying against concrete surfaces. Provide crush or wrecking plates where stripping may damage cast concrete surfaces. Provide top forms for inclined surfaces steeper than 1.5 horizontal to 1 vertical.

Install keyways, reglets, recesses, and the like, for easy removal.

Do not use rust-stained steel form-facing material.

Set edge forms, bulkheads, and intermediate screed strips for slabs to achieve required elevations and slopes in finished concrete surfaces. Provide and secure units to support screed strips; use strike-off templates or compacting-type screeds.

Provide temporary openings for cleanouts and inspection ports where interior area of formwork is inaccessible. Close openings with panels tightly fitted to forms and securely braced to prevent loss of concrete mortar. Locate temporary openings in forms at inconspicuous locations.

Chamfer or round exterior corners and edges of permanently exposed concrete.

Form openings, chases, offsets, sinkages, keyways, reglets, blocking, screeds, and bulkheads required in the Work. Determine sizes and locations from trades providing such items.

Clean forms and adjacent surfaces to receive concrete. Remove chips, wood, sawdust, dirt, and other debris just before placing concrete.

Retighten forms and bracing before placing concrete, as required, to prevent mortar leaks and maintain proper alignment.

Coat contact surfaces of forms with form-release agent, according to manufacturer's written instructions, before placing reinforcement.

EMBEDDED ITEMS

Place and secure anchorage devices and other embedded items required for adjoining work that is attached to or supported by cast-in-place concrete. Use setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded.

Install anchor rods, accurately located, to elevations required and complying with tolerances in Section 7.5 of AISC's "Code of Standard Practice for Steel Buildings and Bridges."

REMOVING AND REUSING FORMS

General: Formwork for sides of beams, walls, columns, and similar parts of the Work that does not support weight of concrete may be removed after cumulatively curing at not less than 50 deg F (10 deg C) for 48 hours after placing concrete, if concrete is hard enough to not be damaged by form-removal operations and curing and protection operations are maintained.

Leave formwork for beam soffits, joists, slabs, and other structural elements that supports weight of concrete in place until concrete has achieved at least 70 percent of its 28-day design compressive strength.

Remove forms only if shores have been arranged to permit removal of forms without loosening or disturbing shores.

Clean and repair surfaces of forms to be reused in the Work. Split, frayed, delaminated, or otherwise damaged form-facing material will not be acceptable for exposed surfaces. Apply new form-release agent.

When forms are reused, clean surfaces, remove fins and laitance, and tighten to close joints. Align and secure joints to avoid offsets. Do not use patched forms for exposed concrete surfaces unless approved by Contracting Officer.

VAPOR RETARDERS

Plastic Vapor Retarders: Place, protect, and repair vapor retarders according to ASTM E 1643 and manufacturer's written instructions.

Lap joints 6 inches (150 mm) and seal with manufacturer's recommended tape.

STEEL REINFORCEMENT

General: Comply with CRSI's "Manual of Standard Practice" for placing reinforcement.

Do not cut or puncture vapor retarder. Repair damage and reseal vapor retarder before placing concrete.

Clean reinforcement of loose rust and mill scale, earth, ice, and other foreign materials that would reduce bond to concrete.

Accurately position, support, and secure reinforcement against displacement. Locate and support reinforcement with bar supports to maintain minimum concrete cover. Do not tack weld crossing reinforcing bars.

Set wire ties with ends directed into concrete, not toward exposed concrete surfaces.

CONCRETE PLACEMENT

Before placing concrete, verify that installation of formwork, reinforcement, and embedded items is complete and that required inspections have been performed.

Before test sampling and placing concrete, water may be added at Project site, subject to limitations of ACI 301.

Deposit concrete continuously in one layer or in horizontal layers of such thickness that no new concrete will be placed on concrete that has hardened enough to cause seams or planes of weakness. If a section cannot be placed continuously, provide construction joints as indicated. Deposit concrete to avoid segregation.

Deposit concrete in horizontal layers of depth to not exceed formwork design pressures and in a manner to avoid inclined construction joints.

Consolidate placed concrete with mechanical vibrating equipment according to ACI 301.

Do not use vibrators to transport concrete inside forms. Insert and withdraw vibrators vertically at uniformly spaced locations to rapidly penetrate placed layer and at least 6 inches (150 mm) into preceding layer. Do not insert vibrators into lower layers of concrete that have begun to lose plasticity. At each insertion, limit duration of vibration to time necessary to consolidate concrete and complete embedment of reinforcement and other embedded items without causing mixture constituents to segregate.

Deposit and consolidate concrete for floors and slabs in a continuous operation, within limits of construction joints, until placement of a panel or section is complete.

Consolidate concrete during placement operations so concrete is thoroughly worked around reinforcement and other embedded items and into corners.

Maintain reinforcement in position on chairs during concrete placement.

Screed slab surfaces with a straightedge and strike off to correct elevations.

Slope surfaces uniformly to drains where required.

Begin initial floating using bull floats or darbies to form a uniform and open-textured surface plane, before excess bleedwater appears on the surface. Do not further disturb slab surfaces before starting finishing operations.

Cold-Weather Placement: Comply with ACI 306.1 and as follows. Protect concrete work from physical damage or reduced strength that could be caused by frost, freezing actions, or low temperatures.

When average high and low temperature is expected to fall below 40 deg F (4.4 deg C) for three successive days, maintain delivered concrete mixture temperature within the temperature range required by ACI 301.

Do not use frozen materials or materials containing ice or snow. Do not place concrete on frozen subgrade or on subgrade containing frozen materials.

Do not use calcium chloride, salt, or other materials containing antifreeze agents or chemical accelerators unless otherwise specified and approved in mixture designs.

Hot-Weather Placement: Comply with ACI 301 and as follows:

Maintain concrete temperature below 90 deg F (32 deg C) at time of placement. Chilled mixing water or chopped ice may be used to control temperature, provided water equivalent of ice is calculated to total amount of mixing water. Using liquid nitrogen to cool concrete is Contractor's option.

Fog-spray forms, steel reinforcement, and subgrade just before placing concrete. Keep subgrade uniformly moist without standing water, soft spots, or dry areas.

FINISHING FORMED SURFACES

As-cast concrete texture imparted by form-facing material, arranged in an orderly and symmetrical manner with a minimum of seams. Repair and patch tie holes and defects. Remove fins and other projections that exceed specified limits on formed-surface irregularities.

Rubbed Finish: Apply the following to smooth-formed finished as-cast concrete where indicated:

Grout-Cleaned Finish: Wet concrete surfaces and apply grout of a consistency of thick paint to coat surfaces and fill small holes. Mix one part portland cement to one and one-half parts fine sand with a 1:1 mixture of bonding admixture and water. Add white portland cement in amounts determined by trial patches so color of dry grout will match adjacent surfaces. Scrub grout into voids and remove excess grout. When grout whitens, rub surface with clean burlap and keep surface damp by fog spray for at least 36 hours.

Related Unformed Surfaces: At tops of walls, horizontal offsets, and similar unformed surfaces adjacent to formed surfaces, strike off smooth and finish with a texture matching adjacent formed surfaces. Continue final surface treatment of formed surfaces uniformly across adjacent unformed surfaces, unless otherwise indicated.

FINISHING FLOORS AND SLABS

General: Comply with ACI 302.1R recommendations for screeding, restraightening, and finishing operations for concrete surfaces. Do not wet concrete surfaces.

Trowel and Fine-Broom Finish: Apply a first trowel finish to surfaces indicated. While concrete is still plastic, slightly scarify surface with a fine broom.

Comply with flatness and levelness tolerances for trowel finished floor surfaces.

Broom Finish: Apply a broom finish to exterior concrete platforms, steps, and ramps, and elsewhere as indicated.

Immediately after float finishing, slightly roughen trafficked surface by brooming with fiber-bristle broom perpendicular to main traffic route. Coordinate required final finish with Contracting Officer before application.

CONCRETE PROTECTING AND CURING

General: Protect freshly placed concrete from premature drying and excessive cold or hot temperatures. Comply with ACI 306.1 for cold-weather protection and ACI 301 for hot-weather protection during curing.

Evaporation Retarder: Apply evaporation retarder to unformed concrete surfaces if hot, dry, or windy conditions cause moisture loss approaching 0.2 lb/sq. ft. x h (1 kg/sq. m x h) before and during finishing operations. Apply according to manufacturer's written instructions after placing, screeding, and bull floating or darbying concrete, but before float finishing.

Formed Surfaces: Cure formed concrete surfaces, including underside of beams, supported slabs, and other similar surfaces. If forms remain during curing period, moist cure after loosening forms. If removing forms before end of curing period, continue curing for the remainder of the curing period.

Unformed Surfaces: Begin curing immediately after finishing concrete. Cure unformed surfaces, including floors and slabs, concrete floor toppings, and other surfaces.

Cure concrete according to ACI 308.1, by one or a combination of the following methods:

Moisture Curing: Keep surfaces continuously moist for not less than seven days with the following materials:

Water.

Continuous water-fog spray.

Absorptive cover, water saturated, and kept continuously wet. Cover concrete surfaces and edges with 12-inch (300-mm) lap over adjacent absorptive covers.

Moisture-Retaining-Cover Curing: Cover concrete surfaces with moisture-retaining cover for curing concrete, placed in widest practicable width, with sides and ends lapped at least 12 inches (300 mm), and sealed by waterproof tape or adhesive. Cure for not less than seven days. Immediately repair any holes or tears during curing period using cover material and waterproof tape.

Moisture cure or use moisture-retaining covers to cure concrete surfaces to receive floor coverings.

Moisture cure or use moisture-retaining covers to cure concrete surfaces to receive penetrating liquid floor treatments.

Cure concrete surfaces to receive floor coverings with either a moisture-retaining cover or a curing compound that the manufacturer certifies will not interfere with bonding of floor covering used on Project..

Curing Compound: Apply uniformly in continuous operation by power spray or roller according to manufacturer's written instructions. Recoat areas subjected to heavy rainfall within three hours after initial application. Maintain continuity of coating and repair damage during curing period.

After curing period has elapsed, remove curing compound without damaging concrete surfaces by method recommended by curing compound manufacturer unless manufacturer certifies curing compound will not interfere with bonding of floor covering used on Project.

FIELD QUALITY CONTROL

Testing and Inspecting: Contractor will engage a qualified independent testing and inspecting agency to perform field tests and inspections and prepare test reports.

Concrete Tests: Testing of composite samples of fresh concrete obtained according to ASTM C 172 shall be performed according to the following requirements:

Testing Frequency: See Table 3.6 in Section 014100. A composite sample set consists of one slump test, one air entrainment test, and one temperature test.

Slump: ASTM C 143/C 143M; one test at point of placement for each composite sample. Perform additional tests when concrete consistency appears to change or water is added.

Air Content: ASTM C 231, pressure method, for normal-weight concrete;one test for each composite sample.

Concrete Temperature: ASTM C 1064/C 1064M; one test for each composite sample.

Compression Test Specimens: ASTM C 31/C 31M. Cast and laboratory cure one set of three standard cylinder specimens for each composite sample.

Compressive-Strength Tests: ASTM C 39/C 39M; test one of three laboratory-cured specimens at 7 days and one specimen at 28 days. If either previous tests fail, test third specimen at 28 days.

Strength of each batch delivered will be satisfactory if 28-day compressive-strength tests equals or exceeds specified compressive strength.

Test results shall be reported in writing to Contracting Officer and Contractor within 48 hours of testing. Reports shall contain project identification name and number, date of concrete placement, name of concrete testing and inspecting agency, location of concrete batch in work, design compressive strength at 28 days, concrete mixture proportions and materials, compressive breaking strength, and type of break for both 7- and 28-day tests.

Additional testing and inspecting, at Contractor's expense, will be performed to determine compliance of replaced or additional work with specified requirements.

Correct deficiencies in the work that test reports and inspections indicate does not comply with the Contract Documents.

CAST-IN-PLACE CONCRETE 033000-10

Upper Baker Site Development

SECTION 221100 - WATER DISTRIBUTION SYSTEMS

1. GENERAL

DW – 1/29/2007 – Need to add HDPE-PVC, HDPE-GSP, and any other required transition fittings. Need to call out by P/N and description, and rule out typical PVC compression fittings. See notes from HDPE Expo (today).

SUMMARY

This Section shall consist of furnishing and installing the following:

Potable water distribution pipe and fittings.

Drains.

This Section shall also include the flushing, testing and disinfection of waterlines.

Related Sections include the following:

Section 024100 “Waste Material Disposal.”

Section 033020 “Concrete From Package Dry Mix for Minor Structures.”

Section 312000 “Earthwork.”

DEFINITIONS

GSP: Galvanized Steel Pipe.

HDPE: High Density Polyethylene plastic.

NPWL: Non-potable waterline (includes sewerline).

PVC: Polyvinyl chloride plastic.

SUBMITTALS

Product Data: For the following:

Pipe and fittings.

Drain and vent screens.

Plan for disposal of water used for testing and disinfection of waterlines.

QUALITY ASSURANCE

All work is to be completed according to applicable Federal, State and Local codes. This work includes, but is not limited to, materials, installation, testing and disinfection Piping materials shall bear label, stamp, or other markings of specified testing agency.

NSF Compliance:

Comply with NSF 14 for plastic potable-water-service piping. Include marking "NSF-pw" on piping.

Comply with NSF 61 for materials for water-service piping and specialties for domestic water.

MINIMUM SYSTEM REQUIREMENTS

Unless otherwise noted, the minimum working pressure for piping and specialties shall be 160 psig.

DELIVERY, STORAGE AND HANDLING

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

Protect stored piping from moisture and dirt. Elevate above grade.

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

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

PROJECT CONDITIONS

Existing Utilities: Do not interrupt utilities serving facilities occupied by the Government or others unless permitted under the following conditions and then only after arranging to provide temporary utility services according to requirements indicated:

Notify the Contracting Officer not less than 5 days in advance of proposed utility interruptions.

COORDINATION

Coordinate connection to existing waterlines with Contracting Officer.

Verify piping materials, sizes, entry locations and pressure requirements are compatible with connection point.

Coordinate other utility impacts.

MEASUREMENT AND PAYMENT

Payment will be lump sum for Water Distribution Systems and will include pipes and fittings, valves, drains, and all other equipment, material, work and incidentals necessary to complete the item.

PRODUCTS

GENERAL

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

PIPES AND FITTINGS

HDPE:

Pipe, AWWA C901:

Material Designation: PE 4710 resin Minimum Cell Classification: ASTM D 3350, 445574C Dimension Ratio and Minimum Pressure Rating: [ IPS ][ CTS ][ DR9, 250 psig][ IPS, SIDR7, 250 psig].

Fittings:

Molded HDPE Fittings: ASTM D 3350, PE 4710 resin, butt-fusion type, made to match HDPE pipe dimensions and class.

Insert Fittings: Not allowed.

Transition Fittings to non-HDPE Pipe: Approved by HDPE pipe manufacturer. Compression-type fittings are not allowed.

Pipe Larger than 2-inch Diameter: Provide in 40-foot lengths rather than in rolls.

Pipe and Fittings 4-inch Diameter and Larger: Conform to AWWA C906 in addition to above requirements.

Pipe Insulation: Urethane foam, 2-inch thick, wrapped around pipe.

Outer Jacket: 60-mil thick HDPE, ASTM D 3350, 345434C cell classification.

PIPING SPECIALTIES

Dielectric Fittings: Combination of copper alloy and ferrous; threaded, solder, or plain end types; and matching piping system materials.

Dielectric Unions: Factory-fabricated union assembly, designed for 250-psig minimum working pressure at 180 deg F. Include insulating material that isolates dissimilar metals and ends with inside threads according to ASME B1.20.1.

Dielectric Flanges: Factory-fabricated companion-flange assembly, for 160- or 300-psig minimum working pressure to suit system pressures.

Dielectric-Flange Insulation Kits: Field-assembled companion-flange assembly, full-face or ring type. Components include neoprene or phenolic gasket, phenolic or polyethylene bolt sleeves, phenolic washers, and steel backing washers.

Provide separate companion flanges and steel bolts and nuts for 150- or 300-psig minimum working pressure to suit system pressures.

Dielectric Couplings: Galvanized-steel couplings with inert and noncorrosive thermoplastic lining, with threaded ends and 300-psig minimum working pressure at 225 deg F).

Dielectric Nipples: Electroplated steel nipples with inert and noncorrosive thermoplastic lining, with combination of plain, threaded, or grooved end types and 300-psig minimum working pressure at 225 deg F.

EXECUTION

EARTHWORK

Refer to Section 312000 “Earthwork” for excavating, trenching, bedding, and backfilling.

PIPING INSTALLATION

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

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

All waterline shall be graded to drain.

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

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

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

Any section of pipe already installed and found to be defective shall be removed and replaced with new pipe at the Contractor’s expense.

Water and Non-Potable/Sewer Line Crossings Potable and NPWL lines shall never be installed in the same trench.

If a new line crosses below an existing line, the existing line shall be supported to prevent settling.

Where waterlines intersect NPWLs or are within 10 horizontal feet of NPWLs, the following applies:

At least one of the pipes (either the waterline or NPWL) shall be constructed or reconstructed with 200 psi pipe or encased in a continuous sleeve with same rating. At crossing, extend 200 psi pipe or sleeve for a distance of 10 feet perpendicular distance from each side of the waterline. The waterline and NPWL pipes or sleeves shall be centered at the crossing so that the joints will be an equal distance and as far as possible from the crossing.

Sleeves: Nominal sleeve diameter to be at least 3 inches larger than nominal diameter of pipe to be encased. Install end seals in annular space at each end of sleeves.

In lieu of constructing or reconstructing the NPWL with pipe conforming to waterline requirements, the NPWL may be encased in concrete at least 6 inches thick around the pipe measured at the bell, for 10 feet each side of the waterline.

Construct according to applicable federal, state and local regulations, including [ California Code of Regulations, “Title 22, Division 4, Chapter 16 “California Waterworks Standards.”][ Idaho Department of Environmental Quality, “Idaho Rules for Public Drinking Water Systems, IDAPA 58.01.08.”][ Nevada State Health Division, “Public Water Systems: Design, Construction, Operation and Maintenance, 445A.65505-6731.”][ Utah Division of Drinking Water, “Rules Governing Public Drinking Water Systems, R309-550.”][ Wyoming Department of Environmental Quality, “Water Quality Rules and Regulations, Chapter 11.”] The Contractor is responsible for obtaining and following these regulations.

Where applicable, state and local regulations supersede the above requirements.

Culvert Crossings: Where waterline crosses a road culvert, adjust grade of waterline to provide a minimum of 12 inches of separation between the waterline and culvert, maintaining slope of waterline to drain.

A minimum of one-foot separation shall be maintained between electric and waterlines in the same trench. Unless the electric conductors are in conduit the waterline shall be a minimum of one foot below the electric conductors.

Bury piping with depth of cover over top at least 36 inches, with top at least 12 inches below level of maximum frost penetration.

Size: As shown on the Drawings.

Placement: Place and form to give the full required support to the pipe. Install so pipe can later be removed from trench without damage to the pipe or the thrust block.

Cutting and Handling of Pipe Cutting of pipe for closure pieces or for other reasons shall be done in a neat manner by methods, which will not damage the pipe. The pipe and fittings shall be handled in such a manner as to insure delivery and final placement in good, undamaged condition. Particular care shall be exercised not to injure the pipe surfaces or coatings. Damaged pipe shall not be used in the work.

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

Do not drop pipe into trench. If HDPE pipe is fusion welded above ground outside of the trench, gently lay pipe into the trench. Ensure installation procedures meet the manufacturer’s requirements.

Pipes shall be placed true to the lines and grades shown on the Drawings and as specified. Complete water system shall be constructed to drain by gravity to drains for seasonal shutdown. Waterlines shall be constructed to drain at a minimum grade of [ 1%][ 2%]. Waterlines not meeting this requirement shall be removed by the Contactor and replaced at no cost to the Government.

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

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

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

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

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

When pipes are installed in a structure or utility box, they shall be adequately supported.

Use proper fittings in order to follow the required line and grades and to avoid excessive curvature. Deflections from a straight line or grade, as required by vertical curves, horizontal curves, or offsets, shall not exceed the manufacturer's recommended maximum joint deflection or curvature for their pipe.

When more than one pipeline is in the same trench, the pipes shall be separated by at least eight horizontal inches, or as shown on the Drawings.

Bends that result in joint tension or permanent pipe deformation are prohibited.

Pipelines may be relocated slightly, if necessary, to avoid existing obstacles. However, the required slopes must be maintained.

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

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

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

Pipe Joints Joints shall be made, using jointing materials and applied with the proper accessories, in accordance with the manufacturer's instructions. Completed joints shall be watertight, and capable of passing the required hydrostatic testing. If pipe and fittings are assembled with a lubricant, it must be nontoxic.

Dissimilar Joints: Connections between two dissimilar pipes or fittings shall be installed in manner recommended by the pipe manufacturer and approved by the Contracting Officer. Use adapters compatible with both piping materials, outer diameters and system working pressure.

For HDPE pipelines:

Use HDPE/GSP transition fittings for connections to galvanized steel pipe.

Stainless steel transition fittings are not to be used on galvanized steel pipe.

Use HDPE/PVC transition fittings for connections to PVC pipe.

For other situations, use fittings to suit the actual conditions.

Compression-type fittings are not allowed.

Threaded Metal Joints:

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

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

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

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

HDPE Heat-Fusion Joints According to ASTM D 2657 and piping manufacturer's written instructions.

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

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

Butt fusion shall be performed between pipe ends or pipe ends and fitting and valve outlets, of like outside diameter and wall thickness, SDR or DR. Butt fusion joining between same diameters but unlike wall thickness shall not be permitted. Transitions between unlike wall thickness shall be made with a transition nipple (a short length of the heavier wall pipe with one end machined to the lighter wall) or by mechanical means.

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

Bent Strap Test: On each day that butt fusions are to be made, perform a “Bent Strap Test.” The first fusion of the day shall be a trial fusion. The trial fusion shall be allowed to cool completely, and then fusion test straps shall be cut out. The test strap shall be 12" (min) or 30 times the wall thickness in length with the fusion in the center, and 1" (min) or 1.5 times the wall thickness in width. Bend the test strap until the ends of the strap touch. If the fusion fails at the joint, a new trial fusion shall be made, cooled completely and tested. Butt fusion of pipe to be installed shall not commence until a trial fusion has passed the bent strap test.

Plastic Piping Solvent-Cemented Joints: Clean and dry joining surfaces. Join pipe and fittings according to the following:

PVC Pressure Piping: Join schedule number ASTM D 1785, PVC pipe and PVC socket fittings according to ASTM D 2672. Join other-than-schedule-number PVC pipe and socket fittings according to ASTM D 2855.

Install piping by directional boring, tunneling, jacking, or combination, under streets and other obstructions that cannot be disturbed.

IDENTIFICATION

According to Section 312000 “Earthwork.”

Wrap all buried, non-metallic, nonperforated piping with tracer wire.

Use detectable warning tape over piping and at outside edges of underground structures.

PIPE SLEEVE INSTALLATION

Where waterline crosses road paving install waterline in pipe sleeve. Extend pipe sleeve a minimum of three feet beyond edge of pavement.

End Seals The annular space between the sleeve or casing and the installed pipe shall be plugged with an end seal to provide a positive seal against a hydrostatic head and prevent soil from entering the space.

HYDROSTATIC TESTING

General The Contractor shall conduct pressure and leakage tests on all newly constructed portions of the water system, including water mains, service lines, fittings, valves, and hydrants. New waterlines that are extensions or modifications of an existing water system shall be tested at the test pressure specified here unless the Contracting Officer specifies another pressure. Pneumatic testing will not be allowed.

The contractor shall ensure that any appurtenance attached to the pipeline at the time of testing is rated to withstand the pressures that will exist during testing.

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

The Contractor shall furnish the pump, pipe, gauge, measuring device, connections, and all other necessary equipment, and shall furnish the necessary personnel to conduct the tests. All equipment, gauges, and attachments shall be subject to approval by the Contracting Officer.

The Contracting Officer shall be present during the testing period.

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

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

Pressure and Leakage Test The test pressure shall:

Equal at least [ 125% of the normal working pressure][ 100 psi][ 125 psi] at the highest elevation of the test but not exceed [ 160][ 200] psi at any point being tested.

Not exceed the thrust restraint design pressures.

Not vary by more than +/- 5 psi from the established test pressure.

Not exceed twice the rated pressure of valves when the test section includes closed valves.

Be not less than 100 psi for all piping within buildings.

Pressure Test Procedure Equipment: The test pressure shall be applied by means of a pump connected to the pipe in a manner satisfactory to the Contracting Officer.

Preparation: Fill pipeline 24 hours before testing. Use only potable water. Each valved section of pipeline shall be slowly filled with water and all air shall be expelled from the pipeline. Apply test pressure to stabilize system.

Pressurization:

Increase pressure in 50-psig increments and inspect each joint between increments.

Hold at test pressure for 1 hour.

Decrease to 0 psig.

Slowly increase again to test pressure and hold for 1 more hour. If the test pressure cannot be sustained within +/- 5 psi during this time, then the system will be determined to have leakage.

Leakage shall be verified by the Contractor and the Contracting Officer.

Locate and repair leaking joints with new materials and repeat test until leakage is within allowed limits. All visible leaks are to be repaired regardless of the amount of leakage.

Examination: All exposed pipe, fittings, valves, and joints shall be carefully examined. Any cracked or defective pipe, fitting, or valve discovered shall be repaired or replaced by the Contractor at his own expense with new material and the test repeated until satisfactory to the Contracting Officer.

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

CLEANING AND DISINFECTION

Clean and disinfect water-distribution piping as follows:

Purge new water-distribution piping systems and parts of existing systems that have been altered, extended, or repaired before use.

Use purging and disinfecting procedure prescribed by authorities having jurisdiction or, if method is not prescribed by authorities having jurisdiction, use procedure described in AWWA C651 or as described below:

Flushing Pipelines After the pressure and leakage testing has been completed, all water pipes shall be thoroughly flushed.

Flushing shall remove all debris from the pipeline, including HDPE pipe shavings, gravel and any other material that may have accidentally entered the pipeline during construction.

Remove all self-closing faucets and drinking fountains from hydrants before flushing lines. Failure to do so will likely clog the internal parts of the faucet.

If no hydrants or other outlets are installed at the end of the waterline, an outlet at the end of each lateral shall be provided. Outlets shall be large enough to develop a velocity in the waterlines of at least 2.5 feet per second (see Table l for necessary flows). If necessary, use a booster pump or other method to obtain the necessary flows.

Minimum velocities must be obtained in all mainlines, laterals and drainlines.

Ensure flushing outlets have adequate drainage and no damage or erosion will occur from the flushing process. Install hoses and/or pipe extensions if necessary.

TABLE 1

Required Flow in Gallons per Minute (GPM) to provide 2.5 feet per second Flushing Velocity

Type of Pipe

Nominal Pipe Size (inches)

HDPE

(SDR 9)

PVC

(160 psi) Galv. Steel (Schedule 40)

Requirement of Chlorination Pipelines: After flushing, all new waterlines and repaired portions of, or extensions to, existing waterlines shall be disinfected by chlorination. Chlorination shall provide a minimum of 25 mg/l residual after 24 hours contact in the system. This may be expected with an application of 50 mg/l, although some conditions may require more. The entire system including the storage tank or spring box shall be filled with the disinfecting solution. All taps, hydrants, and other outlets shall be opened and left open until chlorine is noticeable by odor or testing in the water coming from each. Immediately close taps, hydrants, and other outlets. The chlorinated water shall be retained in the waterlines for at least 24 hours. An alternative of introducing a chlorine solution of 300 mg/l for a period of 3 hours is also approved.

Reservoirs Only: For large reservoirs where water is not going to be reused to disinfect connecting distribution lines, or where it is not economical to treat the entire contents with 50 mg/l of chlorine, disinfection can be accomplished by swabbing or spraying the walls, floor, and ceiling with a chlorine solution containing 300 mg/l of available chlorine. A minimum of 3 hours shall elapse before the structure is flushed and returned to service.

Preparation of Disinfecting Mixture: Chlorine-bearing compounds used for disinfection shall comply with ANSI/NSF 60.

Calcium hypochlorite must be prepared as a water mixture for introduction into the waterlines. The powder should first be made into a paste and then thinned to either a 1 percent or 5.25 percent chlorine solution.

Sodium hypochlorite is already a water mixture.

Table 2 gives the amount of chlorine-bearing compound to mix to obtain either a 1 percent or 5.25 percent solution.

Table 3 gives the amount of a 1 percent or 5.25 percent solution required to obtain a 50 mg/l solution for various volumes.

Table 4 gives the volume of water contained in each 100 feet of pipe of various sizes.

TABLE 2

Amount of Chlorine-bearing Compound to Mix to Obtain a 1% or 5.25% Solution

Water

Water

TABLE 3

Amount of Chlorine-Water Solution Required to make 50 mg/l Chlorine Solution for Various Volumes

Volume (Gallons) 5.25% Solution 1.00% Solution