Attachment_2_-_Specifications.pdf

REPAIR HERCULES STREET PROJECT NO. MAHG171010

CAST IN PLACE CONCRETE

SECTION 03 30 00, Page 1

SECTION 03 30 00

CAST-IN-PLACE CONCRETE

PART 1 GENERAL

1.1 REFERENCES

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

ACI INTERNATIONAL (ACI)

ACI 308 (1992; R 1997) Standard Practice for Curing Concrete

ACI 318/318R (1999) Building Code Requirements for Structural Concrete and Commentary

ACI 347R (1994; R 1999) Guide to Formwork for Concrete

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A 185 (1997) Steel Welded Wire Fabric, Plain, for Concrete Reinforcement

ASTM A 615/A 615M (2000) Deformed and Plain Billet-Steel Bars for Concrete Reinforcement

ASTM C 143/C 143M (2000) Slump of Hydraulic Cement Concrete

ASTM C 150 (1999a) Portland Cement

ASTM C 171 (1997a) Sheet Materials for Curing Concrete

ASTM C 172 (1999) Sampling Freshly Mixed Concrete

ASTM C 231 (1997el) Air Content of Freshly Mixed Concrete by the Pressure Method

ASTM C 260 (2000) Air-Entraining Admixtures for Concrete

ASTM C 309 (1998a) Liquid Membrane-Forming Compounds for Curing Concrete

ASTM C 31/C 31M (2000e1) Making and Curing Concrete Test Specimens in the Field

ASTM C 33 (1999ae1) Concrete Aggregates

ASTM C 39/C 39M (2001) Compressive Strength of Cylindrical Concrete Specimens

Attachment 2

FA301018R0015

SECTION 03 30 00, Page 2

ASTM C 494/C 494M (1999ae1) Chemical Admixtures for Concrete

ASTM C 595 (2000a) Blended Hydraulic Cements

ASTM C 618 (2000) Coal Fly Ash and Raw or Calcined

Natural Pozzolan for Use as a Mineral Admixture in Concrete

ASTM C 685 (2000) Concrete Made by Volumetric Batching and Continuous Mixing

ASTM C 920 (1998) Elastomeric Joint Sealants

ASTM C 94/C 94M (2000e2) Ready-Mixed Concrete

ASTM D 1752 (1984; R 1996el) Preformed Sponge Rubber and

Cork Expansion Joint Fillers for Concrete Paving and Structural Construction

ASTM D 75 (1987; R 1997) Sampling Aggregates

ASTM D 98 (1998) Calcium Chloride

ASTM E 96 (2000) Water Vapor Transmission of Materials

1.2 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with the procedure in the Statement of Work:

SD-03 Product Data

Curing Materials;

Reinforcing Steel;

Expansion Joint Filler Strips, Premolded;

Joint Sealants - Field Molded Sealants;

SD-06 Test Reports

Concrete mix design; G

SD-07 Certificates

Cementitious Materials;

Certificates of compliance attesting that the concrete materials meet the requirements of the specifications shall be submitted in accordance with the Special Clause "CERTIFICATES OF COMPLIANCE".

Cementitious material will be accepted on the basis of a manufacturer's certificate of compliance, accompanied by mill test reports that the material(s) meet the requirements of the specification under which it is furnished.

SECTION 03 30 00, Page 3

Aggregates;

Aggregates will be accepted on the basis of certificates of compliance and tests reports that show the material(s) meet the quality and grading requirements of the specifications under which it is furnished.

1.3 UNIT PRICES: NOT USED

1.4 DESIGN AND PERFORMANCE REQUIREMENTS

The Engineer will maintain the option to sample and test aggregates and concrete to determine compliance with the specifications. The Contractor shall provide facilities and labor as may be necessary to assist the Engineer in procurement of representative test samples. Samples of aggregates will be obtained at the point of batching in accordance with ASTM D 75. Concrete will be sampled in accordance with ASTM C 172. Slump and air content will be determined in accordance with ASTM C 143/C 143M and ASTM C 231, respectively, when cylinders are molded. Compression test specimens will be made, cured, and transported in accordance with ASTM C 31/C 31M. Compression test specimens will be tested in accordance with ASTM C 39/C 39M. Samples for strength tests will be taken not less than once each shift in which concrete is produced. A minimum of three specimens will be made from each sample; two will be tested at 28 days (90 days if pozzolan is used) for acceptance, and one will be tested at 7 days for information.

1.4.1 Strength

Acceptance test results will be the average strengths of two specimens tested at 28 days (90 days if pozzolan is used). The strength of the concrete will be considered satisfactory so long as the average of three consecutive acceptance test results equal or exceed the specified compressive strength, f'c, and no individual acceptance test result falls below f'c by more than 500 psi.

1.4.2 Construction Tolerances

A Class "C" finish shall apply to all surfaces except those specified to receive a Class "D" finish. A Class "D" finish shall apply to all surfaces which will be permanently concealed after construction. The surface requirements for the classes of finish required shall be as specified in ACI 347R.

1.4.3 Concrete Mixture Proportions

Concrete mixture proportions shall be the responsibility of the Contractor.

Mixture proportions shall include the dry weights of cementitious material(s); the nominal maximum size of the coarse aggregate; the specific gravities, absorptions, and saturated surface-dry weights of fine and coarse aggregates; the quantities, types, and names of admixtures; and quantity of water per cubic yard of concrete. All materials included in the mixture proportions shall be of the same type and from the same source as will be used on the project. Specified compressive strength f'c shall be 3,000 psi at 28 days (90 days if pozzolan is used) unless directed otherwise. The maximum nominal size coarse aggregate shall be 1 inch, in accordance with ACI 318/318R. The air content shall be between 4.5 and 7.5 percent. The slump

SECTION 03 30 00, Page 4 shall be between 2 and 5 inches. The maximum water cement ratio shall be 0.50.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Cementitious Materials

Cementitious materials shall conform to the appropriate specifications listed:

2.1.1.1 Portland Cement

ASTM C 150, Type I

2.1.2 Aggregates

Aggregates shall meet the quality and grading requirements of ASTM C 33 Class Designations 4M or better.

2.1.3 Admixtures

Admixtures to be used, when required or approved, shall comply with the appropriate specification listed.

2.1.3.1 Air-Entraining Admixture

Air-entraining admixture shall meet the requirements of ASTM C 260.

2.1.3.2 Accelerating Admixture

Calcium chloride shall meet the requirements of ASTM D 98. Other accelerators shall meet the requirements of ASTM C 494/C 494M, Type C or E.

2.1.3.3 Water-Reducing or Retarding Admixture

Water-reducing or retarding admixture shall meet the requirements of ASTM C 494/C 494M, Type A, B, or D.

2.1.4 Water

Water for mixing and curing shall be fresh, clean, potable, and free from injurious amounts of oil, acid, salt, or alkali.

2.1.5 Reinforcing Steel

Reinforcing steel bar shall conform to the requirements of ASTM A 615/A 615M, Grade 60. Welded steel wire fabric shall conform to the requirements of ASTM A 185. Details of reinforcement not shown shall be in accordance with ACI 318/318R, Chapters 7 and 12.

2.1.6 Expansion Joint Filler Strips, Premolded

Expansion joint filler strips, premolded shall be sponge rubber conforming to ASTM D 1752, Type I.

SECTION 03 30 00, Page 5

2.1.7 Joint Sealants - Field Molded Sealants

Joint sealants - field molded sealants shall conform to ASTM C 920, Type M, Grade NS, Class 25, use NT for vertical joints and Type M, Grade P, Class 25, use T for horizontal joints. Bond-breaker material shall be polyethylene tape, coated paper, metal foil, or similar type materials. The backup material shall be compressible, nonshrink, nonreactive with the sealant, and a nonabsorptive material such as extruded butyl or polychloroprene foam rubber.

2.1.8 Waterstops

Waterstops shall conform to COE CRD-C 572.

2.1.9 Formwork

The design and engineering of the formwork as well as its construction, shall be the responsibility of the Contractor.

2.1.10 Form Coatings

Forms for exposed surfaces shall be coated with a nonstaining form oil, which shall be applied shortly before concrete is placed.

2.1.11 Vapor Barrier

Vapor barrier shall be polyethylene sheeting with a minimum thickness of 6 mils or other equivalent material having a vapor permeance rating not exceeding 0.5 perms as determined in accordance with ASTM E 96.

2.1.12 Curing Materials

Curing materials shall conform to the following requirements.

2.1.12.1 Impervious Sheet Materials

Impervious sheet materials, ASTM C 171, type optional, except polyethylene film, if used, shall be white opaque.

2.1.12.2 Membrane-Forming Curing Compound

ASTM C 309, Type 1-D or 2.

PART 3 EXECUTION

3.1 PREPARATION

3.1.1 General

Construction joints shall be prepared to expose coarse aggregate, and the surface shall be clean, damp, and free of laitance. Ramps and walkways, as necessary, shall be constructed to allow safe and expeditious access for concrete and workmen. Snow, ice, standing or flowing water, loose particles, debris, and foreign matter shall have been removed. Earth foundations shall be satisfactorily compacted. Spare vibrators shall be available. The entire preparation shall be accepted by the Engineer prior to placing.

SECTION 03 30 00, Page 6

3.1.2 Embedded Items

Reinforcement shall be secured in place; joints, anchors, and other embedded items shall have been positioned. Internal ties shall be arranged so that when the forms are removed the metal part of the tie will be not less than 2 inches from concrete surfaces permanently exposed to view or exposed to water on the finished structures. Embedded items shall be free of oil and other foreign matters such as loose coatings or rust, paint, and scale. The embedding of wood in concrete will be permitted only when specifically authorized or directed. All equipment needed to place, consolidate, protect, and cure the concrete shall be at the placement site and in good operating condition.

3.1.3 Formwork Installation

Forms shall be properly aligned, adequately supported, and mortar-tight. The form surfaces shall be smooth and free from irregularities, dents, sags, or holes when used for permanently exposed faces. All exposed joints and edges shall be chamfered, unless otherwise indicated.

3.1.4 Vapor Barrier Installation

Vapor barriers shall be applied over gravel fill. Edges shall be lapped not less than 6 inches. All joints shall be sealed with pressure-sensitive adhesive not less than 2 inches wide. The vapor barrier shall be protected at all times to prevent injury or displacement prior to and during concrete placement.

3.1.5 Production of Concrete

3.1.5.1 Ready-Mixed Concrete

Ready-mixed concrete shall conform to ASTM C 94/C 94M except as otherwise specified.

3.1.5.2 Concrete Made by Volumetric Batching and Continuous Mixing

Concrete made by volumetric batching and continuous mixing shall conform to

ASTM C 685.

3.1.6 Waterstops

Waterstops shall be installed and spliced as directed by the manufacturer.

3.2 CONVEYING AND PLACING CONCRETE

Conveying and placing concrete shall conform to the following requirements.

3.2.1 General

Concrete placement shall not be permitted when weather conditions prevent proper placement and consolidation without approval. When concrete is mixed and/or transported by a truck mixer, the concrete shall be delivered to the site of the work and discharge shall be completed within 1-1/2 hours or 45 minutes when the placing temperature is 85 degrees F or greater unless a retarding admixture is used. Concrete shall be conveyed from the mixer to the forms as rapidly as practicable by methods which prevent segregation or

SECTION 03 30 00, Page 7 loss of ingredients. Concrete shall be in place and consolidated within 15 minutes after discharge from the mixer. Concrete shall be deposited as close as possible to its final position in the forms and be so regulated that it may be effectively consolidated in horizontal layers 18 inches or less in thickness with a minimum of lateral movement. The placement shall be carried on at such a rate that the formation of cold joints will be prevented.

3.2.2 Consolidation

Each layer of concrete shall be consolidated by rodding, spading, or internal vibrating equipment. Internal vibration shall be systematically accomplished by inserting the vibrator through the fresh concrete in the layer below at a uniform spacing over the entire area of placement. The distance between insertions shall be approximately 1.5 times the radius of action of the vibrator and overlay the adjacent, just-vibrated area by a few inches. The vibrator shall penetrate rapidly to the bottom of the layer and at least 6 inches into the layer below, if such a layer exists. It shall be held stationary until the concrete is consolidated and then withdrawn slowly at the rate of about 3 inches per second.

3.2.3 Cold-Weather Requirements

No concrete placement shall be made when the ambient temperature is below 35 degrees F or if the ambient temperature is below 40 degrees F and falling.

Suitable covering and other means as approved shall be provided for maintaining the concrete at a temperature of at least 50 degrees F for not less than 72 hours after placing and at a temperature above freezing for the remainder of the curing period. Salt, chemicals, or other foreign materials shall not be mixed with the concrete to prevent freezing. Any concrete damaged by freezing shall be removed and replaced at the expense of the contractor.

3.2.4 Hot-Weather Requirements

When the rate of evaporation of surface moisture, as determined by use of Figure 1 of ACI 308, is expected to exceed 0.2 pound per square foot per hour, provisions for windbreaks, shading, fog spraying, or covering with a light-colored material shall be made in advance of placement, and such protective measures shall be taken as quickly as finishing operations will allow.

3.3 FORM REMOVAL

Forms shall not be removed before the expiration of 24 hours after concrete placement except where otherwise specifically authorized. Supporting forms and shoring shall not be removed until the concrete has cured for at least 5 days. When conditions on the work are such as to justify the requirement, forms will be required to remain in place for longer periods.

3.4 FINISHING

3.4.1 General

No finishing or repair will be done when either the concrete or the ambient temperature is below 50 degrees F.

SECTION 03 30 00, Page 8

3.4.2 Finishing Formed Surfaces

All fins and loose materials shall be removed, and surface defects including tie holes shall be filled. All honeycomb areas and other defects shall be repaired. All unsound concrete shall be removed from areas to be repaired.

Surface defects greater than 1/2 inch in diameter and holes left by removal of tie rods in all surfaces not to receive additional concrete shall be reamed or chipped and filled with dry-pack mortar. The prepared area shall be brush-coated with an approved epoxy resin or latex bonding compound or with a neat cement grout after dampening and filled with mortar or concrete.

The cement used in mortar or concrete for repairs to all surfaces permanently exposed to view shall be a blend of portland cement and white cement so that the final color when cured will be the same as adjacent concrete.

3.4.3 Finishing Unformed Surfaces

All unformed surfaces that are not to be covered by additional concrete or backfill shall be float finished to elevations shown, unless otherwise specified. Surfaces to receive additional concrete or backfill shall be brought to the elevations shown and left as a true and regular surface.

Exterior surfaces shall be sloped for drainage unless otherwise shown.

Joints shall be carefully made with a jointing tool. Unformed surfaces shall be finished to a tolerance of 3/8 inch for a float finish and 5/16 inch for a trowel finish as determined by a 10 foot straightedge placed on surfaces shown on the plans to be level or having a constant slope. Finishing shall not be performed while there is excess moisture or bleeding water on the surface. No water or cement shall be added to the surface during finishing.

3.4.3.1 Float Finish

Surfaces to be float finished shall be screeded and darbied or bullfloated to eliminate the ridges and to fill in the voids left by the screed. In addition, the darby or bullfloat shall fill all surface voids and only slightly embed the coarse aggregate below the surface of the fresh concrete.

When the water sheen disappears and the concrete will support a person's weight without deep imprint, floating should be completed. Floating should embed large aggregates just beneath the surface, remove slight imperfections, humps, and voids to produce a plane surface, compact the concrete, and consolidate mortar at the surface.

3.4.3.2 Trowel Finish

A trowel finish shall be applied where specified. Trowelling shall be done immediately following floating to provide a smooth, even, dense finish free from blemishes including trowel marks. Finished surfaces shall be protected from damage during the construction period.

3.4.3.3 Broom Finish

A broom finish shall be applied where specified. The concrete shall be screeded and floated to required finish plane with no coarse aggregate visible. After surface moisture disappears, the surface shall be broomed or brushed with a broom or fiber bristle brush in a direction transverse to that of the main traffic or as directed.

3.4.3.4 Edge and Joint Finishing

SECTION 03 30 00, Page 9

All slab edges, including those at formed joints, shall be finished with an edger having a radius of 1/4 inch. Transverse joint shall be edged before brooming, and the brooming shall eliminate the flat surface left by the surface face of the edger. Corners and edges which have crumbled and areas which lack sufficient mortar for proper finishing shall be cleaned and filled solidly with a properly proportioned mortar mixture and then finished.

3.4.3.5 Expansion and Contraction Joints

Expansion and contraction joints shall be made in accordance with the details shown or as otherwise specified. Provide 1/2 inch thick transverse expansion joints where new work abuts an existing concrete. Expansion joints shall be provided at a maximum spacing of 30 feet on center in sidewalks and as shown in slabs and other concrete pavement. Contraction joints shall be provided at a maximum spacing of 5 linear feet in sidewalks as shown in slabs and other concrete pavement. Contraction joints shall be cut at a minimum of one fourth the depth of the paving with a jointing tool after the surface has been finished. Joints will be true to line.

3.5 CURING AND PROTECTION

Beginning immediately after placement and continuing for at least 7 days, all concrete shall be cured and protected from premature drying, extremes in temperature, rapid temperature change, freezing, mechanical damage, and exposure to rain or flowing water. All materials and equipment needed for adequate curing and protection shall be available and at the site of the placement prior to the start of concrete placement. Preservation of moisture for concrete surfaces not in contact with forms shall be accomplished by one of the following methods:

a. Continuous sprinkling or ponding.

b. Application of absorptive mats or fabrics kept continuously wet.

c. Application of sand kept continuously wet.

d. Application of impervious sheet material conforming to ASTM C 171.

e. Application of membrane-forming curing compound conforming to ASTM C 309, Type 1-D, on surfaces permanently exposed to view and Type 2 on other surfaces shall be accomplished in accordance with manufacturer's instructions.

The preservation of moisture for concrete surfaces placed against wooden forms shall be accomplished by keeping the forms continuously wet for 7 days.

If forms are removed prior to end of the required curing period, other curing methods shall be used for the balance of the curing period. During the period of protection removal, the temperature of the air in contact with the concrete shall not be allowed to drop more than 25 degrees F within a 24 hour period.

3.6 TESTS AND INSPECTIONS

3.6.1 General

Concrete testing will be the responsibility of the Contractor. The Contractor shall provide specimens for testing when requested by the

SECTION 03 30 00, Page 10

Engineer. Based upon the results of these inspections and tests, the Contractor shall take required action to correct deficiencies and perform any additional tests to ensure that the requirements of these specifications are met.

3.6.2 Inspection Details and Frequency of Testing

3.6.2.1 Preparations for Placing

Foundation or construction joints, forms, and embedded items shall be inspected in sufficient time prior to each concrete placement by the Contractor to certify that it is ready to receive concrete.

3.6.2.2 Air Content

Air content shall be checked at least once during each shift that concrete is placed. Samples shall be obtained in accordance with ASTM C 172 and tested in accordance with ASTM C 231.

3.6.2.3 Slump

Slump shall be checked once during each shift that concrete is produced.

Samples shall be obtained in accordance with ASTM C 172 and tested in accordance with ASTM C 143/C 143M.

3.6.2.4 Consolidation and Protection

The Contractor shall ensure that the concrete is properly consolidated, finished, protected, and cured.

3.6.3 Action Required

3.6.3.1 Placing

The placing foreman shall not permit placing to begin until he has verified that an adequate number of acceptable vibrators, which are in working order and have competent operators, are available. Placing shall not be continued if any pile is inadequately consolidated.

3.6.3.2 Air Content

Whenever a test result is outside the specification limits, the concrete shall not be delivered to the forms and an adjustment shall be made to the dosage of the air-entrainment admixture.

3.6.3.3 Slump

Whenever a test result is outside the specification limits, the concrete shall not be delivered to the forms and an adjustment should be made in the batch weights of water and fine aggregate. The adjustments are to be made so that the water-cement ratio does not exceed that specified in the submitted concrete mixture proportion.

3.6.4 Reports

The results of all tests and inspections conducted at the project site shall be reported informally at the end of each shift and in writing weekly and

SECTION 03 30 00, Page 11 shall be delivered within 3 days after the end of each weekly reporting period.

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SUBMITTAL PROCEDURES

SECTION 013300, Page 1

SECTION 01330

PART 1 GENERAL

1.1 SUBMITTAL IDENTIFICATION

Submittals required are identified by SD numbers as follows:

SD-01 Data

SD-04 Drawings

SD-06 Instructions

SD-07 Schedules

SD-08 Statements

SD-09 Reports

SD-13 Certificates

SD-14 Samples

SD-18 Records

SD-19 Operation and Maintenance Manuals

1.2 SUBMITTAL CLASSIFICATION

Submittals are classified as follows:

1.2.1 Contracting Officer Approved

Approval is required for extensions of design, critical materials, deviations, equipment whose compatibility with the entire system must be checked, and other items as designated by the Contracting Officer. Within the terms of the Contract Clause entitled "Specifications and Drawings for Construction," they are considered to be "shop drawings."

1.2.2 Information Only

All submittals not requiring approval will be for information only. They are not considered to be "shop drawings" within the terms of the Contract Clause referred to above.

1.3 APPROVED SUBMITTALS

The Contracting Officer's approval of submittals shall not be construed as a complete check, but will indicate only that the general method of construction, materials, detailing and other information are satisfactory.

Approval will not relieve the Contractor of the responsibility for any error which may exist. After submittals have been approved by the Contracting Officer, no resubmittal for the purpose of substituting materials or equipment

SECTION 013300, Page 2 will be considered unless accompanied by an explanation of why a substitution is necessary.

1.4 DISAPPROVED SUBMITTALS

The Contractor shall make all corrections required by the Contracting Officer and promptly furnish a corrected submittal in the form and number of copies specified for the initial submittal. If the Contractor considers any correction indicated on the submittals to constitute a change to the contract, a notice in accordance with the Contract Clause "Changes" shall be given promptly to the Contracting Officer.

PART 2 PRODUCTS (NOT APPLICABLE)

PART 3 EXECUTION

3.1 GENERAL

The Contractor shall make submittals in two copies. The Contracting Officer may request submittals in addition to those specified when deemed necessary to adequately describe the work covered in the respective sections. Units of weights and measures used on all submittals shall be the same as those used in the contract drawings. Each submittal shall be complete and in sufficient detail to allow ready determination of compliance with contract requirements.

Prior to submittal, all items shall be checked and approved by the Contractor's Quality Control (CQC) System Manager and each item shall be stamped, signed, and dated by the CQC System Manager indicating action taken.

Proposed deviations from the contract requirements shall be clearly identified. Submittals shall include items such as: Contractor's, manufacturer's, or fabricator's drawings; descriptive literature including (but not limited to) catalog cuts, diagrams, operating charts or curves; test reports; test cylinders; samples; O&M manuals (including parts list);

certifications; warranties; and other such required submittals. Submittals requiring Contracting Officer approval shall be scheduled and made prior to the acquisition of the material or equipment covered thereby. Samples remaining upon completion of the work shall be picked up and disposed of in accordance with manufacturer's Material Safety Data Sheets (MSDS) and in compliance with existing laws and regulations.

3.2 SUBMITTAL REGISTER

The Contractor shall provide a list of items of equipment and materials for which submittals are required by the specifications. The Contracting Officer may require additional submittals throughout the duration of the contract.

The approved submittal register will become the scheduling document and will be used to control submittals throughout the life of the contract. The submittal register and the progress schedules shall be coordinated.

3.3 SCHEDULING

Submittals covering component items forming a system or items that are interrelated shall be scheduled to be coordinated and submitted concurrently.

Certifications to be submitted with the pertinent drawings shall be so scheduled. Adequate time (a minimum of 20 calendar days exclusive of mailing time) shall be allowed and shown on the register for review and approval. No delay damages or time extensions will be allowed for time lost in late submittals.

SECTION 013300, Page 3

3.4 DEVIATIONS

For submittals which include proposed deviations requested by the Contractor, the Contractor shall set forth in writing the reason for any deviations and annotate such deviations on the submittal.

3.5 CONTROL OF SUBMITTALS

The Contractor shall carefully control his procurement operations to ensure that each individual submittal is made on or before the Contractor scheduled submittal date shown on the approved "Submittal Register."

3.6 APPROVED SUBMITTALS

Upon completion of review of submittals requiring Contracting Officer approval, the submittals will be identified as having received approval by being so stamped and dated. One copy of the submittal will be retained by the Contracting Officer, and the other copy of the submittal will be returned to the Contractor.

3.7 INFORMATION ONLY SUBMITTALS

Normally submittals for information only will not be returned. Approval of the Contracting Officer is not required on information only submittals. The Contracting Officer reserves the right to require the Contractor to resubmit any item found not to comply with the contract. This does not relieve the Contractor from the obligation to furnish material conforming to the plans and specifications; will not prevent the Contracting Officer from requiring removal and replacement of nonconforming material incorporated in the work.

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WATER DISTRIBUTION

SECTION 02510N, Page 1

SECTION 02510N

WATER DISTRIBUTION

09/00

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A 47 (1990) Ferritic Malleable Iron Castings

ASTM A 48 (1994; Rev. A) Gray Iron Castings

ASTM A 53 (1995) Pipe, Steel, Black and Hot-Dipped, Zinc- Coated Welded and Seamless

ASTM A 307 (1994) Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength

ASTM A 536 (1984; R 1993) Ductile Iron Castings

ASTM A 563 (1994) Carbon and Alloy Steel Nuts

ASTM A 746 (1994) Ductile Iron Gravity Sewer Pipe

ASTM B 62 (1993) Composition Bronze or Ounce Metal Castings

ASTM C 94 (1997) Ready-Mixed Concrete

ASTM C 150 (1997; Rev. A) Portland Cement

ASTM D 1785 (1994) Poly(Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120

ASTM D 2241 (1994) Poly(Vinyl Chloride) (PVC) Pressure- Rated Pipe (SDR Series)

ASTM D 2466 (1994; Rev. A) Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 40

ASTM D 2564 (1993) Solvent Cements for Poly(Vinyl Chloride) (PVC) Plastic Piping Systems

ASTM D 2774 (1994) Underground Installation of Thermoplastic Pressure Piping

ASTM D 2855 (1993) Making Solvent-Cemented Joints with Poly(Vinyl Chloride) (PVC) Pipe and Fittings

SECTION 02510N, Page 2

ASTM D 3139 (1995) Joints for Plastic Pressure Pipes Using Flexible Elastomeric Seals

ASTM F 477 (1995) Elastomeric Seals (Gaskets) for Joining

Plastic Pipe

AMERICAN WATER WORKS ASSOCIATION (AWWA)

AWWA C104 (1990) Cement-Mortar Lining for Ductile-Iron

Pipe and Fittings for Water

AWWA C110 (1993) Ductile-Iron and Gray-Iron Fittings, 3

in. Through 48 in. (75 mm Through 1200 mm), for Water and Other Liquids

AWWA C111 (1990; Erratum 1991) Rubber-Gasket Joints for

Ductile-Iron Pressure Pipe and Fittings

AWWA C115 (1994) Flanged Ductile-Iron Pipe with Ductile-

Iron or Gray-Iron Threaded Flanges

AWWA C151 (1991) Ductile-Iron Pipe, Centrifugally Cast, for Water or Other Liquids

AWWA C153 (1994) Ductile-Iron Compact Fittings, 3 in.

Through 24 in. (76 mm Through 610 mm) and 54

in. Through 64 in. (1,000 mm Through 1,600 mm), for Water Service

AWWA C500 (1993) Metal-Seated Gate Valves for Water

Supply Service

AWWA C502 (1994) Dry-Barrel Fire Hydrants

AWWA C503 (1988) Wet-Barrel Fire Hydrants

AWWA C509 (1994) Resilient-Seated Gate Valves for Water and Sewerage Systems

AWWA C600 (1993) Installation of Ductile-Iron Water Mains and Their Appurtenances

AWWA C606 (1987) Grooved and Shouldered Joints

AWWA C651 (1992) Disinfecting Water Mains

AWWA C800 (1989) Underground Service Line Valves and

Fittings

AWWA C900 (1989; Addendum 1992) Polyvinyl Chloride (PVC)

Pressure Pipe, 4 in. Through 12 in., for Water Distribution

AWWA C905 (2010) Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 14 In. through 48 In.

(350 mm through 1,200 mm)

SECTION 02510N, Page 3

AWWA C906 (1990) Polyethylene (PE) Pressure Pipe and Fittings, 4 in. Through 63 in., for Water Distribution

AWWA M23 (1980) PVC Pipe - Design and Installation

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-80 (1987) Bronze Gate, Globe, Angle and Check

Valves

UNI-BELL PVC PIPE ASSOCIATION (UBPPA)

UBPPA UNI-B-3 (1988) Installation of Polyvinyl Chloride (PVC)

Pressure Pipe

UBPPA UNI-B-8 (1986) Direct Tapping of Polyvinyl Chloride

(PVC) Pressure Water Pipe

UNDERWRITERS LABORATORIES (UL)

UL 246 (1993; R 1994, Bul. 1994) Hydrants for Fire-

Protection Service

UL 262 (1994) Gate Valves for Fire-Protection Service

UL 312 (1993; R 1994) Check Valves for Fire-Protection

Service

UL 789 (1993; R 1994) Indicator Posts for Fire-

Protection Service

MISSISSIPPI DEPARTMENT OF HEALTH

(2001) Recommended Minimum Design Criteria for

Mississippi Public Water Systems

1.2 SUBMITTALS

Prerequisite approval is required for submittals with a "PA" designation;

submittals not having a "PA" designation are for information only or as otherwise designated. The following shall be submitted in accordance with Section 01330 SUBMITTAL PROCEDURES:

SD-03 Product Data

Piping Materials, PA

Water distribution main piping, fittings, joints, valves, and coupling

Water service line piping, fittings, joints, valves, and coupling

Hydrants, PA

SECTION 02510N, Page 4

Indicator posts

Corporation stops

Valve boxes

Submit manufacturer's standard drawings or catalog cuts, except submit both drawings and cuts for push-on joints. Include information concerning gaskets with submittal for joints and couplings.

1.3 DELIVERY, STORAGE, AND HANDLING

1.3.1 Delivery and Storage

Inspect materials delivered to site for damage. Unload and store with minimum handling. Store materials on site in enclosures or under protective covering.

Store plastic piping, jointing materials and rubber gaskets under cover out of direct sunlight. Do not store materials directly on the ground. Keep inside of pipes, fittings, valves and hydrants free of dirt and debris.

1.4.2 Handling

Handle pipe, fittings, valves, hydrants, and other accessories in a manner to ensure delivery to the trench in sound undamaged condition. Take special care to avoid injury to coatings and linings on pipe and fittings; make satisfactory repairs if coatings or linings are damaged. Carry, do not drag pipe to the trench.

PART 2 PRODUCTS

2.1 WATER DISTRIBUTION MAIN MATERIALS

2.1.1 Piping Materials

2.1.1.1 Ductile-Iron Piping

a. Pipe and Fittings: Ductile iron pipe shall be designed in accordance with AWWA Specification C150 and manufactured in accordance with AWWA Specification C151. Joints shall conform with AWWA Specification C111 or C115 as applicable and shall be of the push on or mechanical type except where flanged joints are indicated on the plans. Ductile iron pipe 4" and less in diameter shall be of thickness Class 51 and pipe 6" and greater in diameter shall be of thickness Class 50 except pipe with threaded flanges shall be Class 53.

b. Joints and Jointing Material:

(1) Joints: Joints for pipe and fittings shall be mechanical joints unless otherwise indicated.

(2) Push-On Joints: Shape of pipe ends and fitting ends, gaskets, and lubricant for joint assembly, AWWA C111.

(3) Mechanical Joints: Dimensional and material requirements for pipe ends, glands, bolts and nuts, and gaskets, AWWA C111.

SECTION 02510N, Page 5

(4) Flanged Joints: Bolts, nuts, and gaskets for flanged connections as recommended in the Appendix to AWWA C115. Flange for setscrewed flanges shall be of ductile iron, ASTM A 536, Grade 65-45- 12, and conform to the applicable requirements of ASME B16.1, Class

250. Setscrews for setscrewed flanges shall be 190,000 psi tensile strength, heat treated and zinc-coated steel. Gasket for setscrewed flanges, in accordance with applicable requirements for mechanical-joint gaskets specified in AWWA C111. Design of setscrewed gasket shall provide for confinement and compression of gasket when joint to adjoining flange is made.

(5) Insulating Joints: Designed to effectively prevent metal-to-metal contact at the joint between adjacent sections of piping.

Joint shall be of the flanged type with insulating gasket, insulating bolt sleeves, and insulating washers. Gasket shall be of the dielectric type, full face, and in other respects as recommended in the Appendix to AWWA C115. Bolts and nuts, as recommended in the Appendix to AWWA C115.

(6) Sleeve-Type Mechanical Coupled Joints: As specified in paragraph entitled "Sleeve-Type Mechanical Couplings."

(7) Grooved and Shouldered Type Joints: Grooved and shouldered pipe ends and couplings, AWWA C606. Joint dimension shall be as specified in AWWA C606 for rigid joints, except that where joints are indicated to be flexible, joint dimensions shall be as specified for flexible joints.

2.1.1.2 Polyvinyl Chloride (PVC) Plastic Piping

a. Pipe and Fittings: PVC water lines 4 inches through 12 inches shall be "Blue Brute" (blue in color), or an approved equal, Class 150, DR 18 polyvinyl chloride pipe manufactured in accordance with AWWA C-900 (latest edition) and shall be U.L. listed. PVC water lines 14 inches through 48 inches shall be “Big Blue” (blue in color), or approved equal, Class 235, DR 18 polyvinyl chloride pipe manufactured in accordance with AWWA C-905 (latest edition) and shall be U.L. listed.

Pipe shall be furnished in standard lengths (minimum 20 feet) with integrally cast bells or couplings using elastomeric gaskets that meet the requirements of ASTM D 3139 and F-477. All necessary adapters for connection to fittings shall be provided.

b. Joints and Jointing Material: Joints for pipe shall be push-on joints, ASTM D 3139. Joints between pipe and metal fittings, valves, and other accessories shall be push-on joints ASTM D 3139, or compression-type joints/mechanical joints, ASTM D 3139 and AWWA C111.

Provide each joint connection with an elastomeric gasket suitable for the bell or coupling with which it is to be used. Gaskets for push-on joints for pipe, ASTM F 477. Gaskets for push-on joints and compression-type joints/mechanical joints for joint connections between pipe and metal fittings, valves, and other accessories, AWWA C111, respectively, for push-on joints and mechanical joints.

Mechanically coupled joints using a sleeve-type mechanical coupling, as specified in paragraph entitled "Sleeve-Type Mechanical Couplings," may be used as an optional jointing method in lieu of push-on joints on plain-end PVC plastic pipe, subject to the limitations specified for mechanically coupled joints using a sleeve-

SECTION 02510N, Page 6 type mechanical coupling and to the use of internal stiffeners as specified for compression-type joints in ASTM D 3139.

2.1.2 Valves, Hydrants, and Other Water Main Accessories

2.1.2.1 Gate Valves on Buried Piping

AWWA C500, AWWA C509, or UL 262. Unless otherwise specified, valves conforming to: (1) AWWA C500 shall be nonrising stem type with double-disc gates and mechanical-joint ends or push-on joint ends as appropriate for the adjoining pipe, (2) AWWA C509 shall be nonrising stem type with mechanical-joint ends, and (3) UL 262 shall be inside-screw type with operating nut, double-disc or split-wedge type gate, designed for a hydraulic working pressure of 150 psi, and shall have mechanical-joint ends or push-on joint ends as appropriate for the pipe to which it is joined. Materials for UL 262 valves shall conform to the reference standards specified in AWWA C500. Valves shall open by counterclockwise rotation of the valve stem. Stuffing boxes shall have 0-ring stem seals, except for those valves for which gearing is specified, in which case use conventional packing in place of 0-ring seal. Stuffing boxes shall be bolted and constructed so as to permit easy removal of parts for repair. In lieu of mechanical-joint ends and push-on joint ends, valves may have special ends for connection to sleeve-type mechanical coupling. Valve ends and gaskets for connection to sleeve-type mechanical coupling shall conform to the applicable requirements specified for the joint or coupling.

2.1.2.2 Check Valves

Swing-check type, AWWA C508 or UL 312. Valves conforming to: (1) AWWA C508 shall have iron or steel body and cover and flanged ends, and (2) UL 312 shall have cast iron or steel body and cover, flanged ends, and designed for a working pressure of 150 psi. Materials for UL 312 valves shall conform to the reference standards specified in AWWA C508. Valves shall have clear port opening.

2.1.2.3 Fire Hydrants

Dry-Barrel Type Fire Hydrants, Mueller Super Centurion Series 200 or approved equal. Dry-barrel type hydrants, AWWA C502 or UL 246, "Base Valve" design, shall have 6 inch inlet, 5 1/4 inch valve opening, one 4 1/2 inch pumper connection, and two 2 1/2 inch hose connections. Pumper connection and hose connections shall be individually valved with independent nozzle gate valves.

All hydrants shall be "traffic type," shall have breakable features as mentioned in AWWA C503. The traffic type hydrant shall have special couplings joining upper and lower sections of hydrant barrel and upper and lower sections of hydrant stem and shall be designed to have the special couplings break from a force not less than that which would be imposed by a moving vehicle; hydrant shall operate properly under normal conditions. Paint hydrants with at least one coat of primer and two coats of enamel paint to match the Base paint scheme. Stencil hydrant number and main size on the hydrant barrel using black stencil paint.

2.1.2.4 Indicator Posts

UL 789. Provide for gate valves where indicated.

2.1.2.5 Valve Boxes

SECTION 02510N, Page 7

Provide a valve box for each gate valve on buried piping, except where indicator post is shown. Valve boxes shall be of cast iron or precast concrete of a size suitable for the valve on which it is to be used and shall be adjustable. Provide a round head. Cast the word "WATER" on the lid. The least diameter of the shaft of the box shall be 5 1/4 inches. Cast-iron box shall have a heavy coat of bituminous paint.

2.1.2.8 Marking Tape and Tracer Wire for Nonmetallic Piping

All water lines and service lines must be installed with a non-corrosive metallic tape placed directly over and on the center of the facility at a depth of one foot (1’) over the line for its entire length. Tape must be connected to all facilities or appurtenances. The tape shall have a three-inch (3") width and the words "Buried Waterline" should be printed on it along its entire length. Tape shall be Detect tape as manufactured by the Allen Systems, Inc., or approved equal.

All water mains and services shall be installed with a twelve (12) gauge solid copper insulated locator wire placed directly on the center of the main for its entire length. Wire shall be tied to an appurtenance at the start of the new main and shall be a continuous piece of wire for its entire length. The Contractor shall supply the splice kits and other accessories necessary for one continuous locator wire.

2.2 WATER SERVICE LINE MATERIALS

2.2.1 Piping Materials

2.2.1.1 Copper Pipe and Associated Fittings

Pipe, ASTM B 42, regular, threaded ends. Fittings shall be brass or bronze, FS WW-P-460, 125 pound.

2.2.1.2 Copper Tubing and Associated Fittings

Tubing, ASTM B 88, Type K. Fittings for solder-type joint, ANSI B16.18 or ASME B16.22; fittings for compression-type joint, ASME B16.26, flared tube type.

2.2.1.3 Plastic Piping

Polyvinyl Chloride (PVC) Plastic Piping, ASTM D 1785, Schedule 40; or ASTM D 2241, with SDR as necessary to provide 150 psi minimum pressure rating.

Fittings, ASTM D 2466. Pipe and fittings shall be of the same PVC plastic material. Solvent cement for jointing, ASTM D 2564.

2.2.1.5 Insulating Joints

Joints between pipe of dissimilar metals shall have a rubber-gasketed or other suitable approved type of insulating joint or dielectric coupling which will effectively prevent metal-to-metal contact between adjacent sections of piping.

2.2.2 Water Service Line Appurtenances

2.2.2.1 Corporation Stops

Ground key type; bronze, ASTM B 61 or ASTM B 62; and suitable for the working pressure of the system. Ends shall be suitable for solder-joint, or flared

SECTION 02510N, Page 8 tube compression type joint. Threaded ends for inlet and outlet of corporation stops, AWWA C800; coupling nut for connection to flared copper tubing, ASME B16.26.

2.2.2.2 Curb or Service Stops

Ground key, round way, inverted key type; made of bronze, ASTM B 61 or ASTM B 62; and suitable for the working pressure of the system. Ends shall be as appropriate for connection to the service piping. Arrow shall be cast into body of the curb or service stop indicating direction of flow.

2.2.2.3 Gate Valves on Buried Piping

Gate valves 3 inch size and larger on buried piping AWWA C500 or UL 262 and of one manufacturer. Valves, AWWA C500, nonrising stem type with double-disc gates. Valves, UL 262, inside-screw type with operating nut, split wedge or double disc type gate, and designed for a hydraulic working pressure of 175 psi.

2.2.2.4 Gate Valves on Buried Piping

Gate valves smaller than 3-inch size on Buried Piping MSS SP-80, Class 150, solid wedge, nonrising stem. Valves shall have flanged or threaded end connections, with a union on one side of the valve. Provide handwheel operators.

2.2.2.5 Curb Boxes

Provide a curb box for each curb or service stop. Curb boxes shall be of cast iron of a size suitable for the stop on which it is to be used. Provide a round head. Cast the word "WATER" on the lid. Each box shall have a heavy coat of bituminous paint.

2.2.2.6 Valve Boxes

Provide a valve box for each gate valve on buried piping. Valve boxes shall be of cast iron or precast concrete of a size suitable for the valve on which it is to be used and shall be adjustable. Provide a round head. Cast the word "WATER" on the lid. The least diameter of the shaft of the box shall be 5 1/4 inches. Cast-iron box shall have a heavy coat of bituminous paint.

2.2.2.7 Line Stops

Line stops shall include all components required to plug an existing water main so that a newly installed and tested water main can be connected to the existing main currently under pressure. The line stop will allow this connection to occur without the disruption of pressure or service to the existing main upstream of the line stop. Each line stop shall include the following components: Linestop nozzle with closure plug, gate valve, housing unit, high-pressure jackscrew actuator with folding line stop head and miscellaneous gaskets, seals, etc. required to accommodate the line stop operation as shown on the plans.

PART 3 EXECUTION

SECTION 02510N, Page 9

3.1 INSTALLATION OF PIPELINES

3.1.1 General Requirements for Installation of Pipelines

These requirements shall apply to all pipeline installation except where specific exception is made in the "Special Requirements..." paragraphs.

3.1.1.1 Parallel Installation of Water Lines

Water mains and services shall be laid at least ten feet (10') horizontally and eighteen inches (18”) vertically above any existing or proposed sewer main or service. The distance shall be measured edge to edge. Any deviations must be approved by the Engineer on a case-by-case basis, if supported by field data.

3.1.1.2 Crossings

Water mains and services crossing sewers shall be laid to provide a minimum vertical distance of eighteen inches (18") between the outside of the water main and the outside of the sewer. The water main shall be installed above the sewer main. At crossings, one full length of water pipe shall be located so both joints will be as far from the sewer as possible. Special structural support for the water and sewer pipes may be required. If these conditions can not be met, each situation will be reviewed by the Engineer on a case by case basis.

3.1.1.3 Pipe Laying and Jointing

Remove fins and burrs from pipe and fittings. Before placing in position, clean pipe, fittings, valves, and accessories, and maintain in a clean condition. Provide proper facilities for lowering sections of pipe into trenches. Do not under any circumstances drop or dump pipe, fittings, valves, or any other water line material into trenches. Cut pipe accurately to length established at the site and work into place without springing or forcing.

Replace by one of the proper length any pipe or fitting that does not allow sufficient space for proper installation of jointing material. Blocking or wedging between bells and spigots will not be permitted. Lay bell-and-spigot pipe with the bell end pointing in the direction of laying. Grade the pipeline in straight lines; avoid the formation of dips and low points. Support pipe at proper elevation and grade. Secure firm, uniform support. Wood support blocking will not be permitted. Lay pipe so that the full length of each section of pipe and each fitting will rest solidly on the pipe bedding;

excavate recesses to accommodate bells, joints, and couplings. Provide anchors and supports where necessary for fastening work into place. Make proper provision for expansion and contraction of pipelines. Keep trenches free of water until joints have been properly made. At the end of each work day, close open ends of pipe temporarily with wood blocks or bulkheads. Do not lay pipe when conditions of trench or weather prevent installation. Depth of cover over top of pipe shall not be less than 2 1/2 feet.

3.1.1.4 Installation of Tracer Wire

Install a continuous length of tracer wire for the full length of each run of nonmetallic pipe. Attach wire to top of pipe in such manner that it will not be displaced during construction operations.

3.1.1.5 Connections to Existing Water Lines

SECTION 02510N, Page 10

Make connections to existing water lines after approval is obtained and with a minimum interruption of service on the existing line. Make connections to existing lines under pressure in accordance with the recommended procedures of the manufacturer of the pipe being tapped, except as otherwise specified, tap concrete pipe in accordance with AWWA M9 for tapping concrete pressure pipe.

3.1.2 Special Requirements for Installation of Water Mains

3.1.2.1 Installation of Ductile-Iron Piping

Unless otherwise specified, install pipe and fittings in accordance with paragraph entitled "General Requirements for Installation of Pipelines" and with the requirements of AWWA C600 for pipe installation, joint assembly, valve-and-fitting installation, and thrust restraint.

a. Jointing: Make push-on joints with the gaskets and lubricant specified for this type joint; assemble in accordance with the applicable requirements of AWWA C600 for joint assembly.