ESBD_361754_1717708207634_Bid No. 24-28 Project Manual FY 2021 -2022 Sanitary Sewer Replacements_Part3.pdf

MICROTUNNELING AND PIPE-JACKED TUNNELS 2021 STANDARD SPECIFICATION

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3. Completed field forms, such as steering control logs, for checking line and grade of tunneling operation, showing achieved tolerance relative to design alignment.

4. Maximum pipe jacking pressures per drive.

5. Location, elevation and brief soil descriptions of soil strata.

6. Ground water control operations and piezometric levels.

7. Observation of any lost ground or other ground movement.

8. Any unusual conditions or events.

9. Reasons for operational shutdown in event drive are halted.

3.05 EXCAVATION AND JACKING OF PIPE

A. Tunnel Excavation.

1. Keep tunnel excavation within easements and rights-of-way indicated on Drawings and to lines and grades designated on Drawings.

2. Perform tunneling operations in manner that will minimize movement of ground in front of and surrounding tunnel. Prevent damage to structures and utilities above and in vicinity of tunneling operations.

3. Open-face excavations:

a. Keep face breasted or otherwise supported and prevent falls, excessive raveling, or erosion. Maintain standby face supports for immediate use when needed.

b. During shut-down periods, support face of excavation by positive means; no support shall rely solely on hydraulic pressure.

4. Closed-face excavation:

a. Carefully control volume of spoil removed. Advance rate and excavation rate to be compatible to avoid over excavation or loss of ground.

b. When cutting head is withdrawn or is open for any purpose, keep excavated face supported and stabilized.

5. Excavated diameter should be minimum size to permit pipe installation by jacking with allowance for bentonite injection into annular space.

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6. Whenever there is condition encountered which could endanger tunnel excavation or adjacent structures, operate without intermission including 24-hour working, weekends and holidays, until condition no longer exists.

7. Assume responsibility for damage due to settlement from any construction-induced activities.

B. Pipe Jacking

1. Cushion pipe joints as necessary to transmit jacking forces without damage to pipe or pipe joints.

2. Maintain envelope of bentonite slurry around exterior of pipe during jacking and excavation operation to reduce exterior friction and possibility of pipe seizing in place.

3. If pipe seizes up in place and elect to construct recovery access shaft, obtain approval from Project Manager. Coordinate traffic control measures and utility adjustments as necessary prior to commencing work.

4. In event section of pipe is damaged during jacking operation, or joint failure occurs, as evidenced by inspection, visible ground water inflow or other observations, submit for approval his methods for repair or replacement of pipe.

C. Grouting. Grouting requirements are defined in Section 02431 - Tunnel Grout.

3.06 CONTROL OF LINE AND GRADE

A. Construction Control.

1. Project Manager will establish baselines and benchmarks indicated on Drawings.

Check baselines and benchmarks at beginning of Work and report any errors or discrepancies to Project Manager.

2. Use baselines and benchmarks established by Project Manager to establish and maintain construction control points, reference lines and grades for locating tunnel, sewer pipe, and structures.

3. Establish construction control points sufficiently far from work so as not to be affected by ground movement caused by pipe-jacked tunneling operations.

B. Bench Mark Movement. Ensure that if settlement of ground surface occurs during construction which affects accuracy of temporary benchmarks detect and report such movement and reestablish temporary bench marks. Locations of permanent City of Houston monumentation benchmarks are indicated on Drawings. Advise Project Manager of any settlement affecting permanent monumentation benchmarks.

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C. Line and Grade.

1. Check and record survey control for tunnel against above-ground undisturbed reference at least once for each 250 feet of tunnel constructed.

2. Record exact position of MTBM or TBM or shield after each shove to ensure alignment is within specified tolerances. Make immediate correction to alignment before allowable tolerances are exceeded.

3. When excavation is off line or grade, make alignment corrections to avoid reverse grades in gravity sewers.

4. Acceptance criteria for sewer pipe shall be plus or minus 6-inches in horizontal alignment from theoretical at any point between manholes, including receiving end, and plus or minus 1 1/2-inches in elevation from theoretical.

5. Pipe installed outside tolerances and subsequently abandoned shall first be fully grouted.

3.07 MONITORING

A. Instrumentation Monitoring. Instrumentation requirements are shown on Drawings.

Instrumentation specified shall be accessible at all times to Project Manager. Readings shall be submitted promptly to Project Manager.

1. Install and maintain instrumentation system to monitor and detect movement of ground surface and adjacent structures. Establish vertical control points at distance from construction areas that avoids disturbance due to ground settlement.

2. Installation of instrumentation shall not preclude Project Manager, through independent contractor or consultant, from installing instrumentation in, on, near, or adjacent to construction work. Access shall be provided to work for such independent installations.

3. Instruments shall be installed in accordance with Drawings and manufacturer's recommendations.

B. Surface Settlement Monitoring

1. Establish monitoring points on all critical structures.

2. Record location of settlement monitoring points with respect to construction baselines and elevations. Record elevations to accuracy of 0.01 feet for each monitoring point location. Monitoring points should be established at locations and by methods that protect them from damage by construction operations, tampering, or other external influences.

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3. Ground surface elevations shall be recorded on centerline ahead of tunneling operations at minimum of 100-foot intervals or at least three locations per tunnel drive. For sewers greater than 60-inch diameter, also record similar data at approximately 20 feet each side of centerline. Settlement monitoring points must be clearly marked by studs or paint for ease of locating.

4. Railroads. Monitor ground settlement of track subbase at centerline of each track.

5. Utilities and Pipelines. Monitor ground settlement directly above and 10 feet before and after utility or pipeline intersection.

C. Reading Frequency and Reporting. Submit to Project Manager, records of readings from various instruments and survey points.

1. Instrumentation monitoring results to be read at frequency specified and unless otherwise specified, shall be started prior to zone of active excavation reaching that point, and shall be continued until zone of active excavation has passed and until no further detectable movement occurs.

2. Surface settlement monitoring readings shall be taken:

a. Prior to zone of active excavation reaching that point.

b. When tunnel face reaches monitoring point (in plan).

c. When zone of active excavation has passed and no further movement is detected.

3. All monitoring readings shall be submitted promptly to Project Manager.

4. Immediately report to Project Manager any movement, cracking, or settlement which is detected.

5. Following substantial completion but prior to final completion, make final survey of all monitoring points.

3.08 DISPOSAL OF EXCESS MATERIAL

A. Remove spoil in accordance with Section 01576 - Waste Material Disposal.

3.09 ACCEPTANCE TESTING

A. Acceptance testing is to be carried out by methods described in Section 02533 - Acceptance Testing for Sanitary Sewer.

END OF SECTION

2021 STANDARD SPECIFICATION PIPE AND CASING AUGERING FOR SEWERS

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SECTION 02448

PIPE AND CASING AUGERING FOR SEWERS

PART 1 GENERAL

1.01 SECTION INCLUDES

A. Installation of casing for sewer pipe by dry augering or slurry boring methods, together with installation of sewer pipe in casing.

B. Installation of sewer pipe by slurry boring methods. Construction casing may be used at Contractor's option.

1.02 MEASUREMENT AND PAYMENT

A. Unit Prices.

1. Casing, including sewer pipe, installed by augering methods in mid-run of open cut segments where shown on Drawings, will be measured and paid by linear foot from end to end of casing. Casing may be installed, at Contractor's option, at locations other than shown on Drawings, at no additional cost to City.

2. Sewer pipe installed by augering method in mid-run of open-cut segments where shown on Drawings, will be measured and paid by linear foot from end to end of augered section.

3. Pipe or casing segments installed by augering methods in locations other than mid-run of open cut segments and shown on Drawings, will be measured and paid by linear foot along centerline of completed sewer from centerline to centerline of manholes to ends of stubs or termination of pipe, and to inside face of lift stations and other structures.

4. Payment will include and be full compensation for labor, equipment, materials and supervision for excavation and construction of sewer, complete in place including disposal of excess materials, shoring, dewatering, utility adjustments, grouting, backfill, clean-up, and other related work necessary for construction as indicated on Drawings and specified in this Section.

5. Cost for pits and other excavations are included in unit price for pipe with or without casing.

6. Trench safety systems for pits are paid as specified in Section 02260 - Trench Safety Systems.

7. Refer to Section 01270 - Measurement and Payment for unit price procedures.

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B. Stipulated Price (Lump Sum). If Contract is Stipulated Price Contract, payment for work in this Section is included in total Stipulated Price.

1.03 DEFINITIONS

A. Augering means either “dry augering” or “slurry augering”.

B. Dry augering is jacking casing while excavating soil at heading and transporting spoil back through casing by otherwise uncased auger.

C. Slurry Auger Method: Installation of casing or pipe by first drilling small diameter pilot hole from shaft to shaft, followed by removing excess soil and installing pipe or conduit by pull back or jacking method.

1.04 REFERENCE STANDARDS

A. American Railway Engineering and Maintenance-of-Way Association (AREMA) Manual for Railway Engineering.

B. American Association of State Highway and Transportation Officials (AASHTO).

1.05 REGULATORY REQUIREMENTS

A. Conform to Texas State Department of Highways and Public Transportation for installations under state highways. City will obtain required permits for State Highway crossings.

B. Installations under Railroads:

1. Secure and comply with requirements of right-of-entry for crossing railroad company's easement or right-of-way from railroad companies affected. Comply with railroad permit requirements.

2. Use dry auger method only.

3. Damages due to delays caused by railroad requesting work to be done at hours which will not inconvenience the railroad will be at no additional cost to City.

4. Maintain minimum 35-foot clearance from centerline of tracks.

1.06 SUBMITTAL

A. Conform to requirements of Section 01330 - Submittal Procedures.

B. For installation by augering, submit for review:

1. Description of mechanized excavating equipment.

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2. Method of controlling line and grade.

3. Grouting techniques to be used for filling annular void between sewer pipe and casing, and void between sewer pipe or casing and ground, including equipment, pumping and injection procedures, pressure grout types, and mixes.

4. Locations and dimensions of pits.

5. Pit design and construction drawings.

6. Identification of casings required and paid under Contract and casings installed at Contractor's option.

7. Design of casings.

8. Copy of railroad company permits and right-of-entry.

C. Prepare auger pit and casing design submittals that are site specific. Have auger pit and casing design submittals signed and sealed by qualified Professional Engineer registered in State of Texas.

D. Include in construction phase submittals:

1. Daily logs of augering and boring operations.

2. Settlement monitoring data to meet requirements of paragraph 3.05, Settlement Monitoring.

3. Submit daily logs and settlement monitoring data within 5 days after day of observation.

1.07 CRITERIA FOR DETERMINING CASING INSTALLATION LOADS

A. Select and design casing pipe and pipe joints to carry thrust of jacks or loads due to pulling mechanism in combination with overburden, earth and hydrostatic loads. Select casings for dry augering to withstand action of auger without damage.

B. Use Professional Engineer to determine design stresses, design deflections and factors of safety for design of casing. Present such determination as part of design submittal. Apply the following maximum casing pipe stresses and deflections to casings shown on Drawings:

1. Design stress in pipe wall: 50 percent of minimum yield point of steel or 18,000 psi, whichever is less, when subjected to applicable loading conditions.

2. Wall thickness: Maximum allowable deflection which does not exceed 3 percent of nominal casing diameter.

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C. Use Cooper E-80 locomotive loading distributions as criteria for railroad crossings in accordance with AREMA specifications for culverts. In design, account for additive loadings due to multiple tracks.

D. Use HL-93 vehicle loading distributions as criteria for truck loading in accordance with

AASHTO.

E. When not specifically indicated on Drawings, select casing diameter to permit practical installation (including skids when applicable) and grouting.

PART 2 PRODUCTS

2.01 MATERIALS

A. Provide casing pipe which is straight, circular in section, uncoated, welded steel pipe, in accordance with Section 02502 - Steel Pipe and Fittings.

B. Provide sewer pipe in accordance with Section 02531 - Gravity Sanitary Sewers. Do not use high density polyethylene pipe for augering.

C. Provide restrained-joint sewer pipe when installing sewer pipe in slurry bored holes by pull-back method.

D. Supply grout as specified in Section 02431 - Tunnel Grout.

PART 3 EXECUTION

3.01 LOCATION AND SIZE OF AUGER PITS

A. Show location of auger pits on auger pit construction drawings. Locate auger pits for slurry boring so that distance between pits is no greater than 80 feet; and for dry augering not more than 120 feet apart.

B. Locate auger pits and associated work areas to avoid blocking driveways and cross streets and to minimize disruption to business and commercial interests. Avoid auger pit locations near areas identified as potentially contaminated.

C. Make size adequate for construction of structures indicated on Drawings. Provide adequate room to meet Contractor's operational requirements for augering.

D. Provide portable concrete traffic barrier around periphery of pit, meeting applicable safety standards. Properly maintain barrier throughout period pit remains open. Angle traffic barriers in direction of lane flow; do not place barriers perpendicular to on-coming traffic.

E. Provide full cover or other security fencing for each access pit in which there is no construction activity or which is unattended by Contractor's personnel.

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3.02 DRY AUGERING OF CASING

A. Provide jacks, mounted on frame or against backstop, of capacity suitable for forcing excavating auger and casing through soil conditions to be encountered. Operate jacks so that even pressure is applied to casing.

B. Provide steerable front section of casing to allow vertical grade adjustments. Provide water level or other means to allow monitoring of grade elevation of auger casing.

C. Bentonite slurry may be used to lubricate casing during installation. Use of water to facilitate removal of spoil is permitted; however, water jetting for excavation of soil is not allowed when jacking casing.

D. Tolerances from lines and grades shown on Drawings for gravity sewer pipe installed in casing are plus or minus 6 inches in horizontal alignment, and plus or minus 1-1/2 inches in elevation.

3.03 SLURRY BORING OF CASING OR PIPE

A. Drill small diameter pilot hole and check for line and grade at receiving end. Redrill pilot hole when bored pipe does not meet specified tolerances.

B. Using pilot hole as guide bore larger diameter hole of sufficient size for pipe or casing installation. Water jetting is not permitted.

C. Bentonite slurry may be used to maintain stable hole and furnish lubrication for pipe or casing installation.

D. Tolerances from lines and grades shown on Drawings for installed sewer pipe are plus or minus 6 inches in horizontal alignment and plus or minus 1-1/2 inches in elevation.

E. Completely fill annular space between sewer pipe and surrounding soil or casing with grout, without displacing pipe during grouting operation.

3.04 SEWER PIPE IN CASING

A. Grout annular void between sewer pipe and casing from end to end of casing. Block and brace sewer pipe to prevent movement during grout placement and to maintain specified line and grade. Grout as specified in Section 02431 - Tunnel Grout.

3.05 SETTLEMENT MONITORING

A. Monitor ground surface elevation along length of augering operation. Locate and record settlement monitoring points with respect to construction baseline and elevations. Record elevations to accuracy of 0.01 feet for each monitoring point location. Establish monitoring points at locations and by methods that protect them from damage by construction operations, tampering, or other external influences. As minimum, locate survey points as

02448-6 follows:

1. For road crossings: Centerline and each shoulder

2. Railroads: Track subbase at centerline of each track

3. Utilities and Pipelines: Directly above and 10 feet before and after utility or pipeline intersection

4. Long bores under improved areas such as pavements: Ground surface elevations must be recorded on centerline ahead of augering operations at locations not to exceed 50 feet apart (including points located for roads, railroads, utilities, and pipelines), or at least three locations per augering drive

B. Reading Frequency and Reporting. Take settlement survey readings:

1. Prior to auger excavation reaching point

2. After auger reaches monitoring point in plan

3. After grouting of ground supporting pipe or casing is complete

C. Immediately report to Project Manager movement, cracking, or settlement which is detected.

D. Following substantial completion but prior to final completion, make final survey of monitoring points.

3.06 DISPOSAL OF EXCESS MATERIAL

A. Remove and dispose of spoil from job site in accordance with Section 01576 - Waste Material Disposal.

3.07 LEAKAGE TESTING

A. Test sanitary sewers for leakage by low pressure air methods in accordance with Section 02533 - Acceptance Testing for Sanitary Sewer.

STEEL PIPE AND FITTINGS 2021 STANDARD SPECIFICATION

02502-1

SECTION 02502

STEEL PIPE AND FITTINGS

PART 1 GENERAL

1.01 SECTION INCLUDES

A. Steel pipe and fittings for water lines for aerial crossings, aboveground piping, and encasement sleeves. Do not bury steel pipe, unless it is large diameter water line.

B. Specifications identify requirements for small-diameter less than or equal to 20 inches.

1.02 MEASUREMENT AND PAYMENT

A. Unit Prices.

1. No payment will be made for steel pipe and fittings under this Section. Refer to Section 02511 - Water Lines for measurement and payment.

2. Refer to Section 01270 - Measurement and Payment for unit price procedures.

B. Stipulated Price (Lump Sum). If Contract is Stipulated Price Contract, payment for work in this Section is included in total Stipulated Price.

1.03 REFERENCES

A. AASHTO - Standard Specifications for Highway Bridges.

B. ASME B 16.1 - Gray Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and 250

C. ASTM A 36 - Standard Specification for Carbon Structural Steel.

D. ASTM A 53 - Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless.

E. ASTM A 105 - Standard Specification for Carbon Steel Pipe Forgings for Piping Applications.

F. ASTM A 106 - Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service.

G. ASTM A 135 - Standard Specification for Electric-Resistance-Welded Steel Pipe.

STEEL PIPE AND FITTINGS

2021 STANDARD SPECIFICATION

02502-2

H. ASTM A 139 - Standard Specification for Electric-Fusion (ARC) - Welded Steel Pipe (NPS 4 and Over).

I. ASTM A 1011 - Standard Specification for Steel, Sheet and Strip, Hot-Rolled, Carbon, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, and Ultra-High Strength.

J. ASTM D 4541 - Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers

K. AWWA C 200 - Standard for Steel Water Pipe 6 in. and Larger.

L. AWWA C 206 - Standard for Field Welding of Steel Water Pipe.

M. AWWA C 207 - Standard for Steel Pipe Flanges for Waterworks Service - Sizes 4 in.

through 144 in.

N. AWWA C 210 - Liquid-Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines.

O. AWWA C 604 – Installation of Buried Steel Water Pipe – 4 In. (10 mm) and Larger.

P. AWWA M 11 – Steel Pipe – A Guide for Design and Installation.

Q. SSPC Good Painting Practice, Volume 1.

R. SSPC SP 1 - Surface Preparation Specification No. 1 Solvent Cleaning.

S. SSPC SP 5 - Joint Surface Preparation Standard White Blast Cleaning.

T. SSPC SP 6 - Surface Preparation Specification No. 6 Commercial Blast Cleaning.

U. SSPC SP 10 - Surface Preparation Specification No. 10 Near-White Blast Cleaning.

V. SSPC VIS 1 - Visual Standard for Abrasive Blast Cleaned Steel.

1.04 SUBMITTALS

A. Conform to requirements of Section 01330 - Submittal Procedures. For aerial crossings and above ground piping, include lay schedule of new pipe and fittings indicating alignment and grade, laying dimensions, lining and coating systems, proposed welding procedures, fabrication, fitting, flange, and special details. Show station numbers for pipe and fittings corresponding to Drawings.

B. Submit manufacturer's certifications that pipe and fittings are new and unused.

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C. Submit manufacturer's certifications that pipe and fittings have been hydrostatically tested at factory in accordance with AWWA C 200.

D. Submit manufacturer's affidavits that coatings and linings comply with applicable requirements of this Section and:

1. Polyurethane coatings were applied in strict accordance with manufacturer's recommendation and allowed to cure at temperature 5 degrees above dewpoint.

2. Linings were applied and allowed to cure at temperature above 32 F.

E. Submit certification from NACE Certified Coatings Inspector, having Level III certification for coatings and linings, that steel pipe furnished on project was properly inspected and defective coatings detected were properly repaired.

1.05 QUALITY CONTROL

A. Prior to start of work, provide proof of certification of qualification for welders employed for type of work, procedures and positions involved. Provide welder qualifications in accordance with AWWA C 206.

B. Shop-applied coatings and linings; provide services of an independent coating and lining inspection service or testing laboratory with qualified coating inspectors. Perform inspection by NACE trained inspectors under supervision of NACE Level III Certified Coatings Inspector verifying compliance with same requirements specified in Paragraph 3.02.

C. Coatings: Measure temperature and dew point of ambient air before applying coatings.

Inspect physical dimensions and overall condition of coatings. Inspect for visible surface defects, thickness, and adhesion of coating to surface and between layers.

D. Final Inspection:

1. Before shipment, inspect each finished pipe, fitting, special and accessory for markings, metal thickness, coating thickness, lining thickness (if shop applied), joint dimensions, and roundness.

2. Inspect for coating placement and defects. Test exterior coating for holidays.

a. Inspect linings for thickness, pitting, scarring, and adhesion.

E. Ensure workmen engaged in manufacturing are qualified and experienced in performance of their specific duties.

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PART 2 PRODUCTS

2.01 STEEL PIPE

A. Provide steel pipe and encasement sleeves designed and manufactured in conformance with AWWA C 200 and AWWA M 11 except as modified herein. Steel to be minimum of ASTM A106, ASTM A 36, ASTM A 1011 Grade 36, ASTM A 53 Grade B, ASTM A 135 Grade B, or ASTM A 139 Grade B.

B. Minimum Allowable Steel-Wall Thickness:

CARRIER PIPE

Nom Pipe Size

Min. Wall Approx. Wt.

Per L. F.

Uncoated

(Lb.)

O.D (In.)

Thick.

(In.)

4 4.50 0.250 11.35 6 6.625 0.280 18.97 8 8.625 0.322 28.55

10 10.75 0.365 40.48 12 12.75 0.375 49.56 16 16.00 0.375 62.58 20 20.00 0.375 78.60

Notes for Carrier Pipe:

1. Review pipe and fitting design for conditions exceeding those specified herein.

2. Provide pipe with wall thickness of no less than listed in table above.

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MINIMUM DIAMETER CASING PIPE

(ENCASEMENT SLEEVES)

Corresp. Min. Wall Approx. Wt.

Per L. F.

Uncoated

(Lb.)

Casing Pipe O.D Thick.

Size (In.) (In.) (In.)

8 8.625 0.219 19.64 10 10.75 0.219 24.60 12 12.75 0.219 29.28 16 16.00 0.219 36.86 18 18.00 0.25 47.39 20 20.00 0.250 52.73 24 24.00 0.250 63.41

Notes for Casing Pipe:

1. Provide casing pipe with wall thickness of no less than listed in table above.

2. Casing pipe: AWWA C 200 new uncoated welded steel.

3. Verify casing diameter required with dimensions of casing spacer.

C. Provide pipe sections in lengths of no less than 16 feet except as required for special sections, and no greater than 40 feet.

D. Provide short sections of steel pipe no less than 4 feet in length unless indicated on Drawings or specifically permitted by Project Manager.

E. Fittings: Factory forged for sizes 4 inches through 20 inches; long radius bends; beveled ends for field butt welding; wall thickness equal to or greater than pipe to which fitting is to be welded unless otherwise shown on Drawings.

F. Joints:

1. Standard field joint for steel pipe and encasement sleeve: AWWA C 206. Single-welded, butt joint.

2. Electrically isolate flanged joints between steel and cast iron by using flange isolation fittings as specified in paragraph 2.03 of Specification Section 15640 – Joint Bonding and Electrical Isolation. Use epoxy coated nuts and bolts to assemble the fittings.

3. Elbows to be standard weight seamless elbows per ASTM A106, Grade A or B.

G. Flanges: Refer to Specification Section 02511 – Water Lines.

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2.02 INTERNAL LINING SYSTEMS FOR STEEL PIPE, ALL INSTALLATIONS

A. Supply steel pipe with epoxy lining, capable of conveying water at temperatures not greater than 140 degrees F. Provide linings conforming to American National Standards Institute/National Sanitation Foundation (ANSI/NFS) Standard 61 and certification to be from organization accredited by ANSI. Unless otherwise noted, coat exposed (wetted) steel parts of flanges, blind flanges, bolts, access manhole covers, etc., with epoxy lining, as specified.

B. Epoxy Lining AWWA C 210, White, or approved equal for shop and field applied, except as modified in this Section. Provide material from same manufacturer.

Surface Preparation as recommended by manufacturer

SSPC-10

Near White Blast Clean

Finish Coat AWWA C210. Provide Devoe Bar Rust 233H or approved equal.

1. Provide dry film thickness in accordance with product manufacturer recommendations. Do not exceed maximum DFT as recommended by manufacturer.

2. Factory Testing: In accordance with AWWA C210.

2.03 EXTERNAL COATING SYSTEM FOR STEEL PIPE INSTALLED ABOVEGROUND

AND IN VAULTS (EXPOSED)

A. Provide approved epoxy/polyurethane coating system as designated below. Provide material from same manufacturer.

Surface Preparation as recommended by manufacturer

SSPC SP 10

Near White Blast Clean

Intermediate Coat Chemical Resistant Epoxy, or approved equal, AWWA C210

Finish Coat Polyurethane, or approved equal Blue Fed Std. No. 15102 color as approved by Project Manager

B. Total Allowable Dry Film Thickness (DFT) for System: as recommended by manufacturer.

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C. Factory and field testing: in accordance with AWWA C210.

D. Clean bare pipe free from mud, mill lacquer, oil, grease, or other contaminant. Inspect and clean surfaces according to SSPC-SP-1 to remove oil, grease, and loosely adhering deposits prior to blast cleaning. Remove visible oil and grease spots by solvent wiping. Use only approved safety solvents which do not leave residue. Use preheating to remove oil, grease, mill scale, water, and ice provided pipe is preheated in uniform manner to avoid distortion.

E. Remove surface imperfections such as slivers, scabs, burrs, weld spatter, and gouges. Grind weld bead for proper coating application as recommended by coating manufacturer. Presence of metallic defects may be cause for rejection of pipe.

PART 3 EXECUTION

3.01 PIPING INSTALLATION

A. Conform to applicable provisions of Section 02511 - Water lines, except as modified in this Section.

B. Comply with the following:

1. Bedding and Backfilling: Conform to requirements of Section 02317 - Excavation and Backfill for Utilities.

2. For pipes with coating: Do not roll or drag pipe on ground, move pipe in such a manner as not to damage pipe or coating. Carefully inspect pipe for abrasions and repair damaged coating before pipe is installed.

C. Static Electricity:

1. Properly ground steel pipeline during construction as necessary to prevent build-up of static electricity.

2. Electrically test where required after installation is complete.

3.02 EXTERNAL COATING SYSTEM FOR STEEL PIPE INSTALLED ABOVE GROUND

AND IN VAULTS (EXPOSED) AND EPOXY INTERNAL LINING SYSTEM.

A. Safety: Paints, coatings, and linings specified in this Section are hazardous materials. Vapors may be toxic or explosive. Protective equipment, approved by appropriate regulatory agency, is mandatory for personnel involved in painting, coating, and lining operations.

B. Workmanship:

1. Application: By qualified and experienced workers who are knowledgeable in surface

02502-8 preparation and application of high-performance industrial coatings.

2. Paint Application Procedures: SSPC Good Painting Practices, Volume 1.

C. Surface Preparation:

1. Prepare surfaces for painting by using abrasive blasting.

2. Schedule cleaning and painting so that detrimental amounts of dust or other contaminants do not fall on wet, newly-painted surfaces. Protect surfaces not intended to be painted from effects of cleaning and painting operations.

3. Prior to blasting, clean surfaces to be coated or lined of grease, oil and dirt by steaming or detergent cleaning in accordance with SSPC SP 1.

4. Metal and Weld Preparation: Remove surface defects such as gouges, pits, welding and torch-cut slag, welding flux and spatter by grinding to 1/4-inch minimum radius.

5. Abrasive Material:

a. Blast only as much steel as can be coated same day of blasting.

b. Use sharp, angular, properly graded abrasive capable of producing depth of profile specified herein. Transport abrasive to job site in moisture-proof bags or airtight bulk containers. Copper slag abrasives are not acceptable.

c. After abrasive blast cleaning, verify surface profile with replica tape such as Tes-Tex Coarse or Extra Coarse Press-O-Film Tape, or approved equal.

Furnish tapes to Project Manager.

d. Do not blast if metal surface may become wet before priming commences, or when metal surface is less than 5 degrees F above dew point.

6. Evaluate degree of cleanliness for surface preparation with use of SSPC Pictorial Surface Preparation Standards for Painting Steel Surfaces, SSPC-Vis 1.

7. Remove dust and abrasive residue from freshly blasted surfaces by brushing or blowing with clean, dry air. Test cleanliness by placing 3/4-inch by 4-inch piece of clear Scotch type tape on blasted surface, then removing and placing tape on 3x5 white index card. Reclean areas exhibiting dust or residue.

D. Coating and Lining Application:

1. Environmental Conditions: Do not apply coatings or linings when metal temperature is less than 50 degrees F; when ambient temperature is less than 5 degrees F above dew point; when expected weather conditions are such that ambient temperature will drop below 40 degrees F within 6 hours after application; or when relative humidity is

02502-9 above 85 percent. Measure relative humidity and dew point by use of sling psychrometer in conjunction with U.S. Department of Commerce Weather Bureau Psychometric Tables. Provide dehumidifiers for field-applied coatings and linings to maintain proper humidity levels.

2. Application Procedures:

a. Apply in accordance with manufacturer's recommendations and requirements of this Section. Provide finish free of runs, sags, curtains, pinholes, orange peel, fish eyes, excessive over spray, or delaminations.

b. Thin materials only with manufacturers recommended thinners. Thin only amount required to adjust viscosity for temperature variations, proper atomization and flow-out. Mix material components using mechanical mixers.

c. Discard catalyzed materials remaining at end of day.

3. Thoroughly dry pipe before primer is applied. Apply primer immediately after cleaning surface. Apply succeeding coats before contamination of undersurface occurs.

4. Cure a minimum of 24 hours at 77 degrees F before successive coats are applied.

During curing process, provide force air ventilation in volume sufficient to maintain solvent vapor levels below published threshold limit value. Apply successive coats within recoat threshold time as recommended by coating or lining manufacturer on printed technical data sheets or through written communications. Brush blast joints of pipe which have been shop primed and are to receive intermediate and finish coats in field prior to application of additional coats. After interior coatings are applied, provide forced air ventilation in sufficient volume and for sufficient length of time to ensure proper curing before filling pipe with water.

E. Testing of Coatings and Linings:

1. Inspect pipe for holidays and damage to coating:

a. If test indicates no holidays and coating is damaged, remove damaged layers of coating and repair in accordance with coating manufacturer’s recommendations.

2. Perform holiday test in accordance with NACE Standard Recommended Practice, RPO 188-90, Discontinuity (Holiday) Testing of Protective Coatings.

3. Begin testing of completed coating after coating has sufficiently cured, usually one to 5 days. Consult coating manufacturer for specific curing schedule.

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4. Perform adhesion test on pipe in accordance with ASTM D 4541.

5. For coating thickness of 20 mils or less, test with wet sponge low-voltage holiday detector. For coating thickness in excess of 20 mils, test with high-voltage holiday detector. Perform electrical holiday test with 60-cycle current audio detector. Select test voltage as suggested in table below.

MINIMUM VOLTAGES FOR

HIGH VOLTAGE SPARK TESTING

Total Dry Film Thickness

(mils)

Suggested Inspection

(V)

20 to 40

41 to 55 56 to 80

3,000

4,000 6,000

3.03 JOINTS AND JOINTING

A. Welded Joints:

1. Conform to requirements of Section 02511 - Water Lines.

2. Field weld to be full penetration butt welded joints for steel pipe and encasement sleeves for entire circumference.

3. City will employ an independent certified testing laboratory to perform weld acceptance tests on welded joints. Testing Laboratory will test by X-ray methods for butt welds, for 100 percent of joint welds. Project Manager has final decision as to suitability of welds tested.

B. Flanged Joints: Conform to requirements of Section 02511 - Water Lines.

3.04 COATINGS AND LININGS INSPECTION RESPONSIBILITIES

A. Contractor is responsible for quality control of coatings and linings applications and testing and inspection stipulated in this Section. Project Manager is responsible for quality assurance and reserves the right to inspect or acquire services of an independent third-party inspector who is fully knowledgeable and qualified to inspect surface preparation and application of high- performance coatings at all phases of coatings and linings work, field- or shop-applied.

Contractor is responsible for proper application and performance of coatings and linings whether or not Project Manager provides such inspection.

COPPER TUBING

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SECTION 02503

COPPER TUBING

PART 1 GENERAL

1.01 SECTION INCLUDES

A. Copper tubing for water service lines.

1.02 MEASUREMENT AND PAYMENT

A. Unit Prices.

1. No payment will be made for copper tubing under this Section. Include cost in unit price for water taps and service lines.

2. Refer to Section 01270 - Measurement and Payment for unit price procedures.

B. Stipulated Price (Lump Sum). If Contract is Stipulated Price Contract, payment for work in this Section is included in total Stipulated Price.

1.03 REFERENCES

A. ASTM B 88 - Standard Specification for Seamless Copper Water Tube.

B. AWWA C 800 - Standard for Underground Service Line Valves and Fittings.

1.04 SUBMITTALS

A. Conform to requirements of Section 01330 - Submittal Procedures.

B. Submit certified test results of ASTM B 88.

C. Submit manufacturer's testing certification that copper tubing conforms to requirements of ASTM B 88. Number of samples for testing of each size of tubing is modified as follows:

1. For each 7500 feet of tubing: 1 sample

2. For each set of tubing less than 7500 feet: 1 sample

COPPER TUBING 2021 STANDARD SPECIFICATION

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PART 2 PRODUCTS

2.01 MATERIALS

A. Provide Type K annealed, seamless, copper tubing, 3/8 inch to 2 inch in diameter conforming to requirements of ASTM B 88.

B. Provide 3/8-inch and 1-inch tubing in coils of minimum 60 feet in length, and 1-1/2-inch and 2-inch tubing in coils 40 feet in length.

C. Provide tubing manufactured in United States of America. Tubing shall be inspected and tested by laboratory designated by Project Manager at point of manufacture or locally.

Furnish tubing, at no additional cost to designated testing laboratory along with mill compliance certificates.

D. Provide flared or compression-type brass fittings for use with Type K annealed copper tubing in accordance with AWWA C 800.

PART 3 EXECUTION

3.01 INSTALLATION

A. Conform to installation requirements of Section 02512 - Water Tap and Service Line Installation, except as modified in this Section.

3.02 JOINTS

A. Minimum joint spacing for 3/4-inch and 1-inch tubing shall be 60 feet and for 1-1/2-inch and 2-inch tubing shall be 40 feet.

B. Cut copper tubing squarely by using cutting tools designed specifically for purpose and avoid procedures that cause pipe to bend or pipe walls to flatten.

C. After tubing has been cut, but before flaring, use reamer to remove inside rolled lip from tubing. Expand flared ends by use of flaring tool using care to avoid splitting, crimping, or over stressing metal. Provide at least 10 inches of straight pipe adjacent to fittings.

D. When compression fittings are used, cut copper tubing squarely prior to insertion into fitting.

Assemble in accordance with manufacturer's recommended procedure.

3.03 BENDS

A. Bend tubing by using appropriate sized bending tool. No kinks, dents, flats, or crimps shall be permitted. Cut out and replace damaged section. Install no bends with radius smaller than radius of coil of tubing as packaged by manufacturer. Copper tubing shipped in straight lengths conforms to the following:

COPPER TUBING 2021 STANDARD SPECIFICATION

02503-3

1. For 2-inch diameter: Maximum of one 45-degree bend per 4-foot section.

2. For 1-1/2-inch diameter: Maximum of one 45-degree bend per 3-foot section.

POLYVINYL CHLORIDE PIPE 2021 STANDARD SPECIFICATION

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SECTION 02506

POLYVINYL CHLORIDE PIPE

PART 1 GENERAL

1.01 SECTION INCLUDES

A. Polyvinyl chloride (PVC) pressure pipe for water distribution, in nominal diameters 4 inches through 20 inches.

B. Polyvinyl chloride sewer pipe for gravity sewers in nominal diameters 4 inches through 60 inches.

C. Polyvinyl chloride pressure pipe for gravity sewers and force mains in nominal diameters 4 inches through 20 inches.

D. Fusible PVC®, or FPVC®, pipe for pressure pipe in horizontal directional drilling applications up to 20-inches in diameter.

1.02 MEASUREMENT AND PAYMENT

A. Unit Prices.

1. No separate payment will be made for PVC pipe under this Section. Include cost in unit price for work included as specified in the following sections:

a. Section 02511 - Water Lines

b. Section 02531 - Gravity Sanitary Sewers

c. Section 02532 - Sanitary Sewer Force Mains

d. Section 02631 - Storm Sewers

2. Refer to Section 01270 - Measurement and Payment for unit price procedures.

B. Stipulated Price (Lump Sum). If Contract is Stipulated Price Contract, payment for work in this Section is included in total Stipulated Price.

1.03 REFERENCES

A. ANSI A 21.16 (AWWA C 116) - Protective Fusion-Bonded Epoxy Coatings for the Interior and Exterior Surfaces of Ductile-Iron and Gray-Iron.

B. ASTM A 240 - Standard Specification for Chromium and Chromium-Nickel Stainless Steel

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Plate, Sheet, and Strip for Pressure Vessels and for General Applications.

C. ASTM C 923 - Standard Specification for Resilient Connectors Between Reinforced Concrete Manhole Structures, Pipes, and Laterals.

D. ASTM D 618 - Standard Practice for Conditioning Plastics for Testing.

E. ASTM D 1248 - Standard Specification for Polyethylene Plastics Extrusion Materials for Wire and Cable.

F. ASTM D 1784 - Standard Specification for Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl Chloride) (CPVC) Compounds.

G. ASTM D 2122 – Standard Test Method for Determining Dimensions of Thermoplastic Pipe and Fittings.

H. ASTM D 2241 - Standard Specification for Poly (Vinyl Chloride) (PVC) Pressure-Rated Pipe (SDR Series).

I. ASTM D 2321 - Standard Practice for Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity-Flow Applications.

J. ASTM D 2412 – Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel Plate Loading.

K. ASTM D 2444 - Standard Practice for Determination of the Impact Resistance of Thermoplastic Pipe and Fittings by Means of a Tup (Falling Weight).

L. ASTM D 2680 - Specification for Acrylonitrile-Butadiene-Styrene (ABS) and Poly (Vinyl Chloride) (PVC) Composite Sewer Piping.

M. ASTM D 3034 - Specification for Type PSM Poly (Vinyl Chloride) (PVC) Sewer Pipe and Fittings.

N. ASTM D 3139 - Standard Specification for Joints for Plastic Pressure Pipes Using Flexible Elastomeric Seals.

O. ASTM D 3212 - Standard Specification for Joints for Drain and Sewer Plastic Pipes Using Flexible Elastomeric Seals.

P. ASTM F 477 - Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe.

Q. ASTM F 679 - Standard Specification for Poly (Vinyl Chloride) (PVC) Large-Diameter Plastic Gravity Sewer Pipe and Fittings.

R. ASTM F 794 - Standard Specification for Poly (Vinyl Chloride) (PVC) Profile Gravity Sewer Pipe and Fittings Based on Controlled Inside Diameter.

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S. ASTM F 949 - Standard Specification for Poly (Vinyl Chloride) (PVC) Corrugated Sewer Pipe with Smooth Interior and Fittings.

T. AWWA C 110 (ANSI A 21.10) - American National Standard for Ductile-Iron and Gray- Iron Fittings, 3-inch Through 48-inch, for Water and Other Liquids.

U. AWWA C 111 (ANSI A 21.11) - American National Standard for Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings.

V. AWWA C 153 (ANSI A 21.53) - Ductile-Iron Compact Fittings for Water Service.

W. AWWA C900 - Standard for Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 4 In. Through 60 In. (100 MM Through 1,500 MM).

X. AWWA C909 - Standard for Molecularly-Oriented Polyvinyl Chloride (PVCO) Pressure Pipe, 4 In. (100mm) and Larger.

Y. AWWA M23 – PVC Pipe – Design and Installation.

Z. PPI TR-3 - Policies and Procedures for Developing Hydrostatic Design Basis (HDB), Pressure Design Basis (PDB), Strength Design Basis (SDB), and Minimum Required Strength (MRS) Ratings for Thermoplastic Piping Materials or Pipe.

AA. UNI-B-13 - Recommended Standard Performance Specification for Joint Restraint Devices for Use with Polyvinyl Chloride Pipe.

1.04 SUBMITTALS

A. Conform to requirements of Section 01330 - Submittal Procedures.

B. Submit shop drawings showing design of new pipe and fittings indicating alignment and grade, laying dimensions, fabrication, fittings, flanges, and special details.

C. Contractor to review and submit PVC pipe manufacturers recommended installation procedures.

D. Calculations and limits of thrust restraint shall be based on AWWA M23, latest edition.

E. For Fusible PVC® Pipe, submit qualifications of Fusion Technician to be used on the project.

F. Provide manufacturer’s product data for bell insertion protection system.

1.05 QUALITY CONTROL

A. Submit manufacturer's certifications that PVC pipe and fittings meet requirements of this Section and AWWA C900, and AWWA C909 for pressure pipe applications, or appropriate

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ASTM standard specified for gravity sewer pipe.

B. Submit manufacturer's certification that PVC pressure pipe for water lines and force mains has been hydrostatically tested at factory in accordance with AWWA C900and AWWA C909, and this Section.

C. When foreign manufactured material is proposed for use, have material tested for conformance to applicable ASTM requirements by certified independent testing laboratory located in United States. Certification from other source is not acceptable. Furnish copies of test reports to Project Manager for review. Cost of testing paid by Contractor.

D. Fusible PVC®

1. Fusion Technician shall be fully qualified by the pipe supplier to install type(s) and sizes(s) being used. Qualification shall be current as of the actual date of fusion performance on the project.

2. Refer to approved product list for approved manufacturer.

PART 2 PRODUCTS

2.01 MATERIAL

A. Use PVC compounds in manufacture of pipe that contain no ingredient in amount that has been demonstrated to migrate into water in quantities considered to be toxic.

B. Furnish PVC pressure pipe manufactured from Class 12454 virgin PVC compounds as defined in ASTM D 1784. Use compounds qualifying for rating of 4000 psi for water at 73.4 F per requirements of PPI TR-3. Provide pipe which is homogeneous throughout, free of voids, cracks, inclusions, and other defects, uniform as commercially practical in color, density, and other physical properties. Deliver pipe with surfaces free from nicks and scratches with joining surfaces of spigots and joints free from gouges and imperfections which could cause leakage.

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

D. PVC Restrained Pipe: Must be listed on City's current Product Approval List.

1. Pipe Material:

a. Pressure Class 235 psi (DR 18): For restrained joints where shown on Drawings.

b. Pressure Class 305 psi (DR 14): For alternate to offset pipe sections shown on

POLYVINYL CHLORIDE PIPE

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Drawings. Do not use PVC for offset sections with depth of cover greater than 20 feet or less than 4 feet. Do not use PVC in potentially petroleum contaminated areas.

E. Water Service.

1. Provide self-extinguishing PVC pipe that bears Underwriters' Laboratories mark of approval and is acceptable without penalty to Texas State Fire Insurance Committee for use in fire protection lines.

2. Bear National Sanitation Foundation Seal of Approval (NSF-PW).

F. Gaskets:

1. Gasket materials shall meet requirements of ASTM F 477. Use elastomeric factory-installed gaskets to make joints flexible and watertight.

2. Flat Face Mating Flange: Full faces 1/8-inch-thick ethylene propylene (EPR) rubber.

3. Raised Face Mating Flange: Flat ring 1/8-inch ethylene propylene (EPR) rubber, with filler gasket between OD of raised face and flange OD to protect flange from bolting moment.

G. Lubricant for rubber-gasketed joints: Water soluble, non-toxic, non-objectionable in taste and odor imparted to fluid, non-supporting of bacteria growth, having no deteriorating effect on PVC or rubber gaskets.

H. Bell Insertion Protection System: Refer to City of Houston’s Approved Product List.

I. Do not use PVC in potentially or known contaminated areas.

J. Do not use PVC in areas exposed to direct sunlight.

2.02 WATER SERVICE PIPE

A. Pipe 4 inch through 20-inch: AWWA C900, Pressure Class 235 psi (DR 18); AWWA C900, Pressure Class 305 psi (DR 14) as alternate to offset pipe sections; nominal 20-foot lengths;

cast-iron equivalent outside diameters.

B. Provide Polyvinyl Chloride Pipe from manufacturers listed on City of Houston’s Approved Products List.

C. Install trace wire with PVC pipe. Refer to Section 16124 – Conductive Trace Wire for Non- Metallic Water Line Pipes.

D. Make curves and bends by offsetting (i.e., deflecting joints). Do not exceed maximum offset recommended by pipe manufacturer or the City, whichever is less.

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E. Hydrostatic Test: AWWA C900, ANSI A 21.10 (AWWA C 110); at point of manufacture;

submit manufacturer's written certification.

2.03 GRAVITY SEWER PIPE

A. PVC gravity sanitary sewer pipe shall be in accordance with provisions in following table:

WALL

CONSTRUCTION

ASTM

DESIGNATION

SDR (MAX.)/

STIFFNESS (MIN.)

DIAMETER

SIZE RANGE

Solid D3034 SDR 26 / PS 115 6" to 10"

D3034 SDR 35 / PS 46 12" & 15"

F679 SDR 35 / PS 46 18" to 60"

AWWA C900 DR 18 / N/A 4" to 20"

AWWA C909 DR 18 / N/A 4" to 12"

Note: Refer to City of Houston Approved Products List for list of manufacturers.

B. PVC storm sewer pipe shall be in accordance with provisions in following table:

WALL

CONSTRUCTION

MANUFACTURER ASTM

DESIGNATION

SDR (MAX.)/

STIFFNESS (MIN.)

DIAMETER

SIZE RANGE

Solid J-M Pipe CertainTeed Diamond Uponor ETI North American

D3034 SDR 26 / PS 115 6" to 10"

D3034 SDR 35 / PS 46 12" & 15"

F679 SDR 35 / PS 46 18" to 27"

AWWA C900 DR 18 / N/A 4" to 16"

AWWA C909 DR 18 / N/A 4" to 12"

Truss (Gasketed) Contech D2680 N/A /200 psi 8" to 15"

Profile Contech A-2000

Contech A-2026

ETI, Ultra-Rib

ETI, Ultra-Corr

F949

F949

F794

F794

N/A / 46 psi

N/A / 115 psi

N/A / 46 psi

N/A / 46 psi

12" to 36"

8" to 10"

8" to 30"

24" to 36"

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C. When solid wall PVC pipe 18 inches to 27 inches in diameter is required in SDR 26, provide pipe conforming to ASTM F 679, except provide wall thickness as required for SDR 26 and pipe stiffness of 115 psi.

D. For sewers up to…