40_00_51_Buried_Piping_Installation_Add1.docx

INFRASTRUCTURE IMPROVEMENTS FOR THE

SOUTH BAY INTERNATIONAL WASTEWATER TREATMENT PLANT (CC-3)

San Diego County, California

SPECIFICATION 40 00 51

BURIED PIPING INSTALLATION

PART 1 - GENERAL

1.1 RELATED DOCUMENTS, CONTRACT CLAUSES, AND SPECIFICATIONS

The following may not include all related documents, contract clauses, and technical specifications, and does not relieve the Contractor of the responsibility of performing work associated with this specification in accordance with all terms of the Contract herein.

A. Related documents: As described in Specification 00.01.10 Table of Contents Governing.

B. Contract: Section I “Specifications and Drawings for Construction”

C. Other Specifications. Related work specified within the Contract that shall apply to all equipment, materials, labor and services furnished under this Specification shall include, but not be limited to, the following:

· SPECIFICATION 01 33 00, Submittal Requirements

· SPECIFICATION 01 69 00, Transportation, Handling, and Storage of Materials and Equipment

· SPECIFICATION 01 75 01, Starting and Placing Equipment in Operation

· SPECIFICATION 01 75 02, Field Tests of Equipment

· SPECIFICATION 01 78 23, Operation and Maintenance Data

· SPECIFICATION 01 78 36, Warranty

· SPECIFICATION 01 78 39, Project Record Documents

· SPECIFICATION 09 91 00, Painting

· SPECIFICATION 31 05 16, Aggregates for Earthwork

· SPECIFICATION 31 23 00, Excavation and Backfill

· SPECIFICATION 40 00 50, General Piping Provisions

· SPECIFICATION 40 00 62, Steel Pipe - AWWA C200

· SPECIFICATION 40 00 64, Ductile-Iron Pipe

· SPECIFICATION 40 00 82, PVC Pipe - AWWA C900 and C905

· SPECIFICATION 40 00 93, Piping Specialties

· SPECIFICATION 40 00 94, Pipe Markers

(1) All types and sizes of buried piping, specified herein and in other Specifications of these Contract Documents, and shown in the Contract Drawings.

(2) Joint restraint.

(3) Concrete encasement around piping beneath structures.

(4) Connections with existing pipelines.

(5) Protection of existing pipeline.

(6) Testing.

(7) Cleaning and disinfecting.

(8) Disposal of water.

(9) Installation of all jointing and gasketing materials, specials, flexible couplings, mechanical couplings, harnessed and flanged adapters, sleeves, tie rods, closures, end caps, bulkheads, plugs, bolts, nuts, and all other Work required to complete the buried piping installation.

(10) Valves, meters and special items shown or specified shall be incorporated into the piping systems as shown and as specified in the Contract Documents.

(11) Unless otherwise specifically shown, specified, or included under other Specifications, all buried piping Work required, beginning at the outside face of structures or building foundations and extending away from structures or buildings.

B. Coordination:

(1) Review installation procedures under other Specifications and coordinate the Work that must be installed with or attached to the buried piping Work.

(2) Manufacturers and suppliers of the equipment and materials specified herein shall be required to review and satisfy all relevant requirements of other Specifications of the Contract Documents and the requirements of the Contract Drawings. The Contractor, manufacturer, supplier, fabricator and/or subcontractors furnishing and/or installing equipment, materials, services and specialties associated with this Specification shall fully coordinate their efforts to avoid potential claims that are based on failure to review relevant Contract Documents, including the Contract Drawings.

(3) The Contractor shall furnish and install all equipment, labor, materials, appurtenances, specialty items and services not provided by the Contractor’s manufacturers, suppliers, fabricators and/or subcontractors but required for complete and operable systems.

1.3 QUALIFICATIONS, DESIGN STANDARDS, AND REFERENCES

A. Manufacturer's Qualifications:

(1) Manufacturers of each piping system shall have a minimum of 5 years of experience producing pipe and fittings, and shall show evidence with their submittal of at least 5 installations in satisfactory operation. The qualifying installations shall consist of facilities with the approximate extent of pipe and fittings as this project.

(2) Pipe and fittings of each type of piping system shall be the product of one manufacturer.

B. Standard Specifications for Public Works Construction, 2006 (SSPWC): Some work specified herein is subject to conform to the requirements of Section 306-1 of the SSPWC. Where there is a conflict between the SSPWC and these Technical Specifications, provisions of these Technical Specifications shall govern.

C. International Building Code, 2006 (IBC): The Contractor shall comply with the provisions of the IBC.

D. Other Reference Industry Standards / Specifications: Reference / industry standards shall apply to all equipment, materials, labor and services furnished under this Specification shall include, but not be limited to, the following:

(1) American Society of Civil Engineers (ASCE) Manual of Practice (MOP) No. 37, Design and Construction of Sanitary and Storm Sewers

(2) American Society for Testing and Materials (ASTM) B32 - 08 Standard Specification for Solder Metal

(3) ASTM D2321 - 05 Standard Practice for Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity-Flow Applications.

(4) ASTM D2774 - 08 Standard Practice for Underground Installation of Thermoplastic Pressure Piping.

(5) American Water Works Association (AWWA) C105 / A21.5-05, American National Standard for Polyethylene Encasement for Ductile-Iron Pipe Systems.

(6) AWWA C111 / A21.11-07 American National Standard for Rubber Gasket Joints for Ductile Iron Pressure Pipe and Fittings.

(7) AWWA C200-05 Standard for Steel Water Pipe – 6 In. (150mm) and Larger

(8) AWWA C206-03 Standard for Field Welding of Steel water Pipe

(9) AWWA C302-04 Standard for Reinforced Concrete Pressure Pipe, Noncylinder Type

(10) AWWA C600-05, Standard for Installation of Ductile-Iron Water Mains and Their Appurtenances.

(11) AWWA C606-06, Standard for Grooved and Shouldered Type Joints.

(12) AWWA C651-05 Standard for Disinfecting Water Mains.

(13) AWWA C900-07, Standard for Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 4 In. Through 12 In., for Water Transmission and Distribution.

(14) AWWA C905-97, Polyvinyl Chloride (PVC) Water Transmission Pipe, Nominal Diameters 14 In. Through 36 In.

(15) AWWA C907-04, Standard for Injection-Molded Polyvinyl Chloride (PVC) Pressure Fittings, 4 In. Through 8 In. (100 mm Through 200 mm), for Water Distribution.

(16) AWWA M9 (1995), Concrete Pressure Pipe, 2nd Edition.

(17) AWWA M11 (2004), Steel Water Pipe: A Guide for Design and Installation, Fourth Edition.

(18) AWWA M23 (2002) PVC Pipe - Design and Installation.

(19) American Concrete Pipe Association - Concrete Pipe Handbook (2007).

(20) Copper Development Association, Inc., Copper Brass Bronze Product Handbook

(21) NFPA Standard No. 24 (2007), Standard for the Installation of Private Fire Service Mains and Their Appurtenances.

(22) Underwriters Laboratories Incorporated (UL), Factory Mutual (FM) and other jurisdictional authorities, where applicable.

1.4 SUBMITTALS

The Contractor shall submit the following to the COR in accordance with the requirements and procedures specified in Specification 01 33 00, Submittal Requirements, and in this Specification.

A. Shop Drawings: The Contractor shall submit to the COR for compliance-confirmation the following, as a minimum:

(1) Laying schedules and detailed layout drawings for all piping 6 inches in diameter or greater, and all secondary containment piping reflecting the Contractor's construction schedule and installation methods. The laying schedules and layout drawings shall be referenced to the stationing and elevations or coordinates as shown on the Contract Drawings, and all layout drawings shall be prepared to scale. Each pipe joint, length, fitting and special shall be designated on the layout drawings and in the laying schedules. Pipe closures shall be included in the layout drawings. Pipe, fittings and specials delivered to the job site shall be marked with the same letter or number designation appearing on the layout drawings and in the laying schedules.

(2) Locations of restrained joints shall be included in the layout schedules and detailed layout drawings.

(3) Full details of connections to existing pipelines and structures, and pipe closures, including dimensions, sizes, classes, etc.

(4) Detailed description of the proposed pipe handling and installation methods; copies of these descriptions shall be furnished to the pipe manufacturer for use in pipe design.

(5) Detailed descriptions of proposed field testing including information and data pertaining to procedures and apparatus.

(6) For connections with and protection of existing pipelines, the Contractor shall refer to Specification 40 00 50, General Piping Provisions.

B. Tests: Refer to testing of piping as specified herein.

C. Certificates: The Contractor shall submit certificates of compliance with referenced standards.

D. Record Drawings: During progress of the Work, the Contractor shall keep an up-to-date set of drawings showing field and shop drawing modifications. The drawings shall show all piping on plans and in sections, with all reference dimensions and elevations required for complete record drawings regardless whether the piping was shown on the Contract Drawings. The Contractor shall refer to Specification 01 78 39, Project Record Documents; and Specification 40 00 50, General Piping Provisions.

E. Manufacturer's Qualifications: The Contractor shall submit to the COR for compliance-confirmation, the Manufacturer’s Qualifications in accordance with Part 1.3 herein.

1.5 MEASUREMENT AND PAYMENT

The work performed by the Contractor under this Specification shall not be measured and paid for directly, but shall be considered to be included in the Lump Sum Bid for this Contract.

PART 2 – MATERIALS, EQUIPMENT, AND/OR PRODUCT

2.1 MATERIALS

Required pipe materials are listed in the Buried Piping Schedule as identified in Part 3.9 herein; refer to applicable Specifications for material specifications. The Contractor shall conform to requirements of the schedule, unless otherwise specified and shown in the Contract Documents. For marking piping, refer to Specification 40 00 94, Pipe Markers.

2.2 DELIVERY, STORAGE AND HANDLING

Delivery, storage and handling of materials, equipment and/or products shall be per the requirements of Specification 01 69 00, Transportation, Handling, and Storage of Materials and Equipment. The Contractor shall deliver materials to the site to ensure uninterrupted progress of the Work, and shall comply with manufacturer's recommendations for handling, storage and protection during the progress of the Work.

The Contractor shall furnish and install all equipment, labor, materials, appurtenances, specialty items and services not provided by the Contractor's manufacturers, suppliers, fabricators and/or subcontractors but required for complete and operable systems.

A. The Contractor shall refer to Specification 40 00 50, General Piping Provisions.

B. The Contractor shall handle all pipe, fittings, specials and accessories carefully with compliance-confirmed handling devices. Do not drop or roll material off trucks. Do not otherwise drop, roll or skid piping.

C. The Contractor shall store pipes and fittings on heavy wood blocking or platforms so they are not in contact with the ground.

D. The Contractor shall unload pipe, fittings and specials opposite to or as close to the place where they are to be installed as is practical to avoid unnecessary handling. Keep pipe interiors completely free from dirt and foreign matter.

E. Materials cracked, gouged, chipped, dented or otherwise damaged will not be acceptable and shall be removed from the site immediately by the Contractor.

F. Thermoplastic pipe shall be stored by the Contractor so as to prevent sagging or bending.

G. Thermoplastic pipe, fittings and specials shall not be stored in direct sunlight.

H. Products cracked, gouged, chipped, dented or otherwise damaged will not be accepted or compliance-confirmed and shall be removed and replaced at the Contractor's expense, unless the product can be repaired in a manner acceptable to the manufacturer and COR. All repairs shall be at the Contractor's expense.

PART 3 – CONSTRUCTION OR EXECUTION METHOD

3.1 INSTALLATION

A. General:

(1) Installation of all pipe, fittings, valves, specials and appurtenances shall be subject to the review and compliance-confirmation of the COR.

(2) Install piping as shown, specified and as recommended by the manufacturer and in conformance with referenced standards, and compliance-confirmed Shop Drawings.

(3) The COR has the option of inspecting all piping prior to installation. COR'S inspection will not relieve the Contractor or manufacturer from responsibility for damaged products.

(4) All piping shall be carefully examined for cracks, damage or other defects before installation. Any piping that is defective, including but not limited to, cracked, damaged, in poor condition, or with damaged linings or improperly marked shall be rejected by the COR. Any piping found to be broken or defective after it has been installed shall be removed and replaced at the Contractor’s expense.

(5) Minimum earth cover over the piping shall be as shown on the Contract Drawings, specified or directed by the COR.

(6) Required earthwork shall be as specified in Specification 31 23 00, Excavation and Backfill.

(7) Present all conflicts between piping systems and equipment, structures or facilities to COR for determination of corrective measures before proceeding.

(8) Take field measurements where required prior to installation to ensure proper fittings of Work.

(9) Interiors of all piping and mating surfaces shall be inspected and all dirt, gravel, sand, debris or other foreign material shall be completely removed from the interior and mating surfaces before installation. Measures shall be taken to maintain the interior of all piping clean until acceptance of the completed Work. Care shall be taken to prevent foreign matter from entering joint space. Bell and spigot mating surfaces shall be wiped clean immediately before piping is laid. For ductile iron pipe, the bell and spigot mating surfaces shall be thoroughly cleaned with a wire brush.

(10) Install piping accurately to line and grade as shown or specified, unless otherwise compliance-confirmed by the COR. Accurate means of determining and checking the alignment and grade shall be used, which shall be subject to the compliance-confirmation of the COR.

(11) Do not lay piping in water, unless otherwise specified in these Specifications or compliance-confirmed by the COR. Ensure that the water level in the trench is at least 6 inches below the bottom of piping. Maintain a dry trench until jointing and backfilling are complete, unless otherwise specified in these Specifications or compliance-confirmed by the COR.

(12) Where unforeseen conditions will not permit the installation of piping as shown or specified, no piping shall be installed without compliance-confirmation of the COR. Do not modify structures or facilities without compliance-confirmation of the COR.

(13) Start laying piping at lowest point and proceed toward the higher elevations, unless otherwise compliance-confirmed by the COR. Slope piping uniformly between elevations shown on the Contract Drawings or as otherwise provided by the COR.

(14) Place bell and spigot piping so that the bells face the direction of laying, unless otherwise compliance-confirmed by the COR.

(15) Piping shall be installed so that the barrel of the piping and not the joints, receives the bearing pressure from the trench bottom, or other bedding condition.

(16) No piping shall be brought into position until the preceding length, valve, fitting, or special has been bedded and secured in place.

(17) Whenever pipe laying is not actively in progress, the open ends of the piping shall be closed by a temporary plug or cap to prevent soil, water and other foreign matter from entering the piping.

(18) Field cutting of metallic piping, where required for inserting valves, fitting, specials, and closures, shall be made with a machine specially designed for cutting piping and in accordance with the manufacturer's instructions. Cuts shall be carefully done, without damage to piping, so as to leave a smooth end at right angles to the axis of the piping. Cut end shall be tapered and sharp edges filed off smooth. Flame cutting shall not be permitted. Piping damaged by the Contractor by improper or careless methods of cutting shall be replaced or repaired at the Contractor’s expense.

(19) Blocking under piping will not be permitted unless specifically compliance-confirmed by COR for special conditions.

(20) Damaged protective linings and coatings shall be touched up in a satisfactory manner prior to installation, where required.

(21) Except where bends, wyes or similar fittings are used, changes in alignment and grade of the piping shall be made by deflecting joints or with beveled pipe. Permissible joint deflection shall not exceed 75 percent (75%) of the amount allowed by the manufacturer.

(22) All joints shall be subject to inspection by the COR.

(23) Special care shall be taken to ensure that each section of piping abuts against the next in such a manner that there will be not shoulder or unevenness of any kind along the piping invert.

(24) Piping shall be rotated as required to place outlets in proper position.

(25) Plugs, caps, blind flanges and cleanouts shall be provided at locations shown on the Contract Drawings, specified or required. Cleanouts on buried piping shall include all pipe, fittings and appurtenances required to bring cleanout to finished grade and terminate in a flange and blind flange or suitably capped piping as shown. Cleanout piping shall be same as that specified for the main run.

(26) All gravity lines shall pitch uniformly at slope 1/4-inch per foot or at the slope shown on the Contract Drawings, or specified.

(27) Short pipe stubs, maximum 4 feet in length, shall be used at all manholes and other wall faces, except as otherwise specified.

(28) Field painting shall be accomplished after joints are made.

(29) All piping shall be plugged watertight with a suitable cap or plug securely fastened to the end of the piping at all contract interfaces where applicable.

(30) Piping located underneath concrete buildings or structures shall have concrete encasement unless otherwise noted on the Contract Drawings.

B. Manufacturer's Installation Specialist:

(1) The Contractor shall provide at the Contractor’s expense the services of a competent manufacturer's installation specialist when pipe laying commences, if the Contractor is not experienced in laying and jointing a particular type of pipe.

(2) Retain specialist on the job for a minimum of 8 hours or until a sufficient amount of pipe has been laid and jointed to demonstrate to the specialist and the COR the competency of the pipe laying crew.

C. Separation of Sewers and Potable and Fire Waterlines: The Contractor shall conform to requirements of the San Diego Health Department Guidelines.

D. Plugs:

(1) Temporarily plug installed pipe at the end of each day's work, or other interruption to progress on a given line. Plugging shall be adequate to prevent entry of small animals, liquids, or persons into the pipe or the entrance or insertion of deleterious materials.

(2) Insert standard plugs into all deadend pipes, tees, or crosses; spigot ends shall be capped.

(3) Plugs installed for pressure testing shall be fully secured and blocked to withstand the test pressure.

(4) Where plugging is required because of contract division or phasing for later connection, the ends of such lines shall be equipped with a watertight, permanent type plug. Installation or removal of such plugging will be considered incidental to the Work.

E. Bedding Pipe: Bedding shall conform to details shown and to the following:

(1) Piping shall be bedded in conformance with Specification 31 05 16, Aggregates for Earthwork, and as shown on the Contract Drawings, except as otherwise specified.

(2) Trench Bedding: Trench bedding for all concrete pipe shall be Class C with a granular foundation as shown on the Contract Drawings.

(3) Excavation in excess of that required as shown on the Contract Drawings or specified, which is not authorized by the COR, shall be at the Contractor’s expense. Backfilling and compaction of the over-excavated areas shall be at the Contractor’s expense. Select granular fill shall be used to refill the over-excavated areas.

(4) Backfilling and compaction of pipe bedding and cover shall be as shown on the Contract Drawings and specified in Specification 31 23 00, Excavation and Backfill.

(5) Carefully and thoroughly compact all pipe bedding and fill up to the pipe centerline with hand held pneumatic compactors.

(6) No pipe shall be laid until the COR compliance-confirms the bedding condition. Consult with COR if a conflict exists in bedding details.

(7) No pipe shall be brought into position until the preceding length has been bedded and secured in its final position.

F. Laying Pipe:

(1) Conform to manufacturer's instructions and requirements of the standards listed below, where applicable:

(a) Ductile Iron Pipe: AWWA C105, AWWA C600.

(b) Reinforced Concrete Pipe: AWWA Manual of Practice M9.

(c) Reinforced Concrete Pressure Pipe: AWWA Manual of Practice M9.

(d) Steel Pipe (Effluent Piping): AWWA Manual of Practice M11.

(e) Thermoplastic Pipe: ASTM D2774.

(f) ASCE Manual of Practice No. 37.

(2) Use implements, tools and facilities to protect the pipe. Handle pipe in such a manner as to avoid any damage to the pipe.

(3) Use only fabric straps to lift pipe; do not use chains or cables. Do not drop, dump or roll pipe into trenches.

(4) Install all pipe accurately to line and grade as shown on the Contract Drawings unless otherwise compliance-confirmed by COR. Remove and relay pipes that are not laid correctly.

(5) Slope piping uniformly between elevations shown.

(6) Ensure that ground water level in trench is at least 6 inches below bottom of pipe before laying piping. Do not lay pipe in water. Maintain dry trench conditions until jointing and backfilling are complete and protect and keep clean water pipe interiors, fittings and valves.

(7) Start laying pipe at lowest point and proceed towards the higher elevations, unless otherwise compliance-confirmed by COR.

(8) Place bell and spigot pipe so that bells face the direction of laying, unless otherwise compliance-confirmed by COR.

(9) Place concrete pipe containing elliptical reinforcement with the minor axis of the reinforcement in a vertical position.

(10) Place polyvinyl chloride (PVC) lined concrete pipe with the longitudinal liner seam shall be located at the invert of the pipe.

(11) Excavate around joints in bedding and lay pipe so that the barrel bears uniformly on the trench bottom.

(12) Deflections at joints shall not exceed 75 percent (75%) of the amount allowed by the pipe manufacturer.

(13) For copper tubing and thermoplastic piping, snake piping in trench to compensate for thermal expansion.

(14) Carefully examine all pipe, fittings and specials for cracks, damage or other defects while suspended above the trench before installation. Immediately remove defective materials from site.

(15) Inspect interior of all pipe and fittings and completely clean all dirt, gravel, sand, debris or other foreign material from pipe interior and joint recesses before it is moved into the trench. Bell and spigot mating surfaces shall be thoroughly wire brushed, and wiped clean and dry immediately before the pipe is laid.

(16) Field cut pipe, where required, with a machine specially designed for cutting piping. Make cuts carefully, without damage to pipe or lining, and with a smooth end at right angles to the axis of pipe. Cut ends on push-on joint shall be tapered and sharp edges filed off smooth. Flame cutting will not be allowed.

(17) Blocking under piping will not be permitted unless specifically compliance-confirmed by COR for special conditions. If permitted, conform to requirements of AWWA C600.

(18) Damaged protective linings and coatings shall be touched up in a satisfactory manner prior to backfilling.

(19) The Contractor shall notify COR in advance of backfilling operations.

(20) On steep slopes, take measures acceptable to COR to prevent movement of the pipe during installation.

(21) Thrust Restraint: During the installation of the pipe, restrained joint systems, restrained joints, restraint harnesses and tied joints shall be provided wherever required for thrust restraint. Thrust restraint shall conform to the applicable requirements of Thrust Restraint, of this Specification.

(22) Concrete thrust blocks will not be permitted.

(23) Exercise care to avoid flotation when installing pipe in castin-place concrete.

F. Concrete Encasement: All piping underneath structures and concrete slabs shall be encased in reinforced concrete. Concrete encasement shall be installed per the typical pipe encasement details shown on the Contract Drawings.

G. Polyethylene Encasement:

(1) All buried ductile iron, steel and cast iron piping, values, fittings and appurtenances shall be wrapped in polyethylene encasement to prevent contact between the pipe and surrounding bedding material and backfill.

(2) All buried mechanical couplings shall be wrapped in polyethylene encasement.

(3) Polyethylene may be supplied in tubes or in sheet material.

(4) Polyethylene encasement materials and installation shall be in accordance with the requirements of AWWA C105. Materials shall be in accordance with Paragraph 4.1.2. of AWWA C105. For tubes, use Method A installation.

H. Cathodic Protection: Non-Applicable.

I. Jointing Pipe:

(1) Ductile Iron Mechanical Joint Fittings:

(a) Wipe clean the socket, plain end and adjacent areas immediately before making joint. Make certain that cut ends are tapered and sharp edges are filed off smooth.

(b) Lubricate the plain ends and gasket with soapy water or a compliance-confirmed pipe lubricant, in accordance with AWWA C111, just prior to slipping the gasket onto the plain end of the joint assembly.

(c) Place the gland on the plain end with the lip extension toward the plain end, followed by the gasket with the narrow edge of the gasket toward the plain end.

(d) Insert the pipe into the socket and press the gasket firmly and evenly into the gasket recess. Keep the joint straight during assembly.

(e) Push gland toward socket and center it around pipe with the gland lip against the gasket.

(f) Insert bolts and hand tighten nuts.

(g) Make deflection after joint assembly, if required, but prior to tightening bolts. Alternately tighten bolts 180 degrees apart to seat the gasket evenly. The bolt torque shall be as follows:

Pipe Size (inches) Bolt Size (inches) Range of Torque (foot-pounds)

(2) Ductile Iron Push-On Joint Pipe:

(a) Prior to assembling the joints, the last 8 inches of the exterior surface of the spigot and the interior surface of the bell shall be thoroughly cleaned with a wire brush, except where joints are lined or coated with a special protective lining or coating.

(b) Rubber gaskets shall be wiped clean and flexed until resilient. Refer to manufacturer's instructions for procedures to ensure gasket resiliency when assembling joints in cold weather.

(c) Insert gasket into joint recess and smooth out the entire circumference of the gasket to remove bulges and to prevent interference with the proper entry of the spigot of the entering pipe.

(d) Immediately prior to joint assembly, apply a thin film of compliance-confirmed lubricant to the surface of the gasket which will come in contact with the entering spigot end of pipe. The Contractor may, at his option, apply a thin film of lubricant to the outside of the spigot of the entering pipe.

(e) For assembly, center spigot in the pipe bell and push pipe forward until it just makes contact with the rubber gasket. After gasket is compressed and before pipe is pushed or pulled all the way home, carefully check the gasket for proper position around the full circumference of the joint. Final assembly shall be made by forcing the spigot end of the entering pipe past the rubber gasket until it makes contact with the base of the bell. When more than a reasonable amount of force is required to assemble the joint, the spigot end of the pipe shall be removed to verify the proper positioning of the rubber gasket. Gaskets which have been scoured or otherwise damaged shall not be used.

(f) Maintain an adequate supply of gaskets and joint lubricant at the site at all times when pipe jointing operations are in progress.

(3) Mechanical Couplings Joints: Prior to the installation and assembly of mechanical couplings, the joint ends shall be cleaned thoroughly with a wire brush to remove foreign matter. Following this cleaning, lubricant shall be applied to the rubber gasket or inside of the coupling housing and to the joint ends. After lubrication, the gasket shall be installed around the joint end of the previously installed piece and the joint end of the subsequent piece shall be mated to the installed piece. The gasket shall be positioned and the coupling housing placed around the gasket and over the grooved or shouldered joint ends. The bolts shall be inserted and the nuts screwed up tightly by hand. The bolts shall then be tightened uniformly in order to produce an equal pressure on all parts of the housing. When the housing clamps meet metal to metal, the joint is complete and further tightening is not required.

(4) Thermoplastic Pipe (PVC, chlorinated polyvinyl chloride (CPVC) and polyvinylidene difluoride (PVDF)) Joints:

(a) Socket Weld Joints:

1. General: The procedure below is to be used as a guide. However, the compliance-confirmed pipe manufacturer's recommended procedures shall be followed unless the procedures listed below are more stringent.

2. Cut pipe square with mitre box or plastic tube cutter.

3. Chamfer pipe end to a 10 to 15 degree angle.

4. Clean and dry socket of all dirt, moisture and grease.

5. Check dry fit of pipe in fitting. Pipe should enter socket about 1/3 to 3/4 depth.

6. Dissolve inside socket surface by brushing with primer. Use brush 1/2 the size of pipe diameter. Use a scrubbing motion to assure penetration. Repeat application as necessary.

7. Dissolve surface of male end of pipe to be inserted into socket to depth of fitting socket by brushing on liberal coat of primer. Be sure entire surface is well dissolved.

8. Brush inside socket with primer one more time, then without delay apply proper cement liberally to male end of pipe. The amount of cement should be more than sufficient to fill any gap.

9. Apply proper cement lightly to inside of socket. Keep excess cement out of socket to prevent solvent damage to pipe. Apply a second coat of cement to the pipe end.

10. While both inside socket and outside surface of male end of pipe are soft and wet with cement, forcefully bottom the male end of pipe into socket, giving the male a one-quarter turn. The pipe must go to the bottom of the socket. Hold joint together until both surfaces are firmly gripped (minimum 30 seconds).

11. After assembly, wipe excess cement from the pipe at the end of the fitting socket. A properly made joint will normally show a bead around its entire perimeter. Any gaps at this point may indicate a defective assembly job, due to insufficient cement, or use of light bodied cement on large diameters where heavy bodied cement should have been used. Reassembly will be required if assembly is determined to be defective.

12. Do not disturb joint until setup of the cement occurs. Refer to manufacturer's solvent cement set time schedule for setup times at various ambient temperatures.

(b) Gasketed Push-On Joints:

1. Bevel all field-cut pipe, remove all burrs and provide a reference mark the correct distance from the pipe end.

2. Clean the pipe end and the bell thoroughly before making the joint. Insert the O-ring gasket, making certain it is properly oriented. Lubricate the spigot well with a compliance-confirmed lubricant; do not lubricate the bell or O-ring. Insert the spigot end of the pipe carefully into the bell until the reference mark on the spigot is flush with the bell.

(5) Reinforced Concrete Pipe (RCP) Joints - Storm Drain:

(a) Clean completely all jointing surfaces and adjacent areas immediately before making joint. If flexible joint protector is to be used in lieu of mortar joint protection, place the protector over the spigot behind the gasket groove.

(b) Apply a thin layer of lubricant supplied by the pipe manufacturer to the sealing surfaces of the bell and spigot and the gasket. After lubrication, install the gasket in the spigot groove, and equalize the stretch by inserting a smooth rod under the gasket and moving the rod rapidly around the full circumference of the spigot.

(c) Support the pipe being lowered into the trench so that the jointing effort is a straight in pull. The jointing effort can be supplied by come-a-longs, backhoe or crane with laying sling, or winches. The use of excavating equipment to shove pipe sections together will not be permitted unless provisions are made to prevent localized over-stressing of the pipe joints, and these provisions are compliance-confirmed by the COR. On pipe 24 inches and larger, joint stoppers should be inserted in the joint by an inside man to hold the joint 5/8 inch open, while an internal feeler gage is used to check the gasket. If the gasket is not in place, the joint must be disassembled and relaid using a new gasket. If the gasket is found to be in proper position with the feeler gage, the joint stoppers should be pulled and the joint shoved all the way home. On pipe 20 inches and smaller, the joint should be laid home without stoppers, and an external feeler gage used to check the gasket. When a joint opening is needed to make a grade or alignment adjustment, the joint should be laid "home" first, then opened as required on one side. All joint openings must be within the recommended limits of the pipe manufacturer.

(d) The exterior joints shall not be mortared.

(e) The interior joint recess of pipe 24 inches and larger shall be pointed using a stiff 1:3 Portland cement mortar. The inside surface shall be struck off smooth with the pipe interior.

(6) Reinforced Concrete Pressure Pipe (RCPP) Joints:

(a) Clean completely all jointing surfaces and adjacent areas immediately before making joint.

(b) Exterior joint spaces shall be grouted in conformance to AWWA M9.

(7) Steel Pipe Joints, AWWA C200 piping:

(a) Clean completely all jointing surfaces and adjacent areas immediately before making joint.

(b) Conform to AWWA M11.

(8) Steel Pipe Joints, Schedule 40 piping:

(a) Joints in steel pipe shall be butt welded joints, except that flexible couplings, mechanical couplings, or flanged connections shall be provided at connections to valves, meters, and similar equipment.

(b) Welding shall conform to the requirements of AWWA C206.

(c) After welding, the joint and the surrounding damaged or uncoated area shall be coated with the same material and to the same thickness as the shop applied coating.

(d) Where flanged connections or couplings are provided, the flanges, couplings, bolts and nuts shall be painted per Specification 09 91 00, Painting.

(9) Copper Tubing Joints:

(a) Assemble copper tubing with soldered joints. Solder shall be 95-5 tin-antimony solder conforming to ASTM B32.

(b) Ream or file pipe to remove burrs.

(c) Clean and polish contact surfaces of joints.

(d) Apply flux to both male and female ends.

(e) Insert end of tube into full depth of fitting socket.

(f) Heat joint evenly.

(g) Form continuous solder bead around entire circumference of joint.

(h) Runs shall contain unions at connection to equipment and at reasonable distances along the lengths of runs to permit convenient disassembly of piping and removal of equipment.

J. Copper Pipe Installation - Supplementary Requirements:

(1) Trench bottom shall be tamped to line and grade. Remove all sharp stones and rocks in trench bottom; replace and tamp with clean earth.

(2) For long lines use annealed temper to permit long runs with a minimum of joints. Snake piping to absorb line expansion.

(3) Use proper jointing methods as recommended by the Copper Development Association, Inc., Copper Brass Bronze Product Handbook, to prevent joint corrosion.

(4) Backfill with tamped, clean earth free from stones, cinders, or other materials which could cause damage or corrosion to piping.

(5) A wrapping of polyethylene shall be applied to pipe.

(6) Connections between copper and cast iron or ductile iron pipelines shall be joined by a dielectric (insulated) pipe union. The gasket, when the joint is made, shall not project into the internal opening. The pipelines shall be connected so that the electrical current is below 1 percent (1%) of the galvanic current. The union shall be suitable for the working pressure of the line on which installed.

K. Backfilling:

(1) Conform to the applicable requirements of Specification 31 23 00, Excavation and Backfill and the Contract Drawings.

(2) Place backfill as construction progresses. Backfill by hand and use power tampers until pipe is covered by at least one foot of fill.

L. Connections to Valves and Hydrants:

(1) Install valves and hydrants as shown on the Contract Drawings.

(2) Provide suitable adapters when valves or hydrants and piping have different joint types.

(3) Provide thrust restraint at all hydrants and at all valves.

M. Transitions from One Type of Pipe to Another: The Contractor shall provide all necessary adapters, specials and connection pieces required when connecting different types and sizes of pipe or connecting pipe made by different manufacturers, or of different material.

N. Closures: The Contractor shall provide all closure pieces shown or required to complete the Work. Locate closures in horizontal, straight runs of pipe.

3.2 THRUST RESTRAINT

A. Provide thrust restraint on all pressure piping systems where specified and shown on the Contract Drawings. For pipelines with restrained joints, refer to the Buried Piping Schedule.

B. Thrust restraint shall be accomplished by means of restrained pipe joints as specified. Thrust restraints shall be designed for the axial thrust exerted by the test pressure specified in the Buried Piping Schedule.

C. Concrete thrust blocks will not be permitted.

D. Restrained Pipe Joints: Pipe joints shall be restrained by means suitable for the type of pipeline being installed.

(1) Ductile iron pipe and fittings utilizing restrained push-on joints, refer to Specification 40 00 64, Ductile-Iron Pipe.

(2) PVC C900 and C905 pipe, with ductile iron mechanical joint fittings and valves utilizing restrained joint retainer glands, refer to Specification 40 00 82, PVC Pipe - AWWA C900 and C905.

(3) PVC C900 and C905 bell and spigot pipe joints utilizing restraint harnesses, refer to Specification 40 00 82, PVC Pipe - AWWA C900 and C905 Pipe.

(4) Steel C200 pipe utilizing harnessed joints, refer to Specification 40 00 62, Steel Pipe - AWWA C200.

E. Restrained Pipe Joints Locations: Restrained pipe joints shall be located by the Contractor in pipelines as follows:

(1) Ductile iron push-on joints: At all fittings and valves, and 50-foot minimum in each direction at each fitting and valve.

(2) Mechanical joint fittings with PVC C900 and C905 piping: At all fittings and valves.

(3) PVC C900 and C905 pipe joints: 50-foot minimum in each direction at each fitting and valve.

(4) Steel C200 piping: At all fittings and valves, and where shown on the Contract Drawings.

3.3 PAINTING

Painting shall be as specified in Specification 09 91 00, Painting.

3.4 WORK AFFECTING EXISTING PIPELINES

For connection with and protection of existing pipelines, refer to Specification 40 00 50, General Piping Provisions. The Contractor shall notify the COR in writing at least 15 calendar days prior to taking pipelines out of service.

3.5 TESTING OF PIPING

A. Field Testing:

(1) Test all piping except as otherwise authorized by COR.

(2) Notify COR 48 hours prior to the commencement of testing.

(3) Provide all testing apparatus, including pumps, hoses, gages, and fittings.

(4) Pipelines shall hold specified test pressure for 4 hours, unless otherwise noted.

(5) Pipelines which fail to hold specified test pressure or which exceed the allowable leakage rate shall be repaired and retested.

(6) Test pressures required are at the lowest elevation of the pipeline section being tested, unless otherwise specified.

(7) All blind flanges, bulkheads, plugs and end caps shall be in place during testing.

(8) Conduct all tests in the presence of COR.

(9) Advise local authorities having jurisdiction if their presence is required during testing.

(10) All tests shall be repeated until the test conditions are satisfied.

(11) Water Source: The source of the water, and the point of introduction of water for conducting tests, shall be subject to compliance-confirmation of the COR.

(12) All costs for tests shall be included in the Contractor's bid.

B. Schedule of Pipeline Tests:

(1) Test piping at the test pressure listed in the Buried Piping Schedule.

(2) All piping shall be water tested after installation except as otherwise specified or directed by the COR.

(3) Piping not in schedule shall be tested at 20 psig greater than its maximum operating pressure.

C. Pressure Test Procedure:

(1) Complete backfill and compaction at least to the pipe centerline before testing, unless otherwise required or compliance-confirmed by COR.

(2) Prior to testing, all pipelines shall be flushed or blown out as appropriate.

(3) The pipelines shall be tested either in sections or as an entire unit. No section of the pipeline shall be tested until all field placed concrete or mortar has obtained an age of 14 days. The test shall be made by closing valves where available, or by placing temporary bulkheads in the pipe and filling the line slowly with water. All temporary bulkheads shall be suitably restrained to resist the thrust of the test pressure without damage to, or movement of, the adjacent pipe.

(4) All air vents, where available, shall remain open during filling. All air release and vacuum valves, in all water lines, shall be operational prior to testing.

(5) The pipeline shall be filled at a rate which will not cause any surges or exceed the rate at which the air can be released through the air release valves at a reasonable velocity and all the air within the pipeline shall be properly purged.

(6) The maximum filling rate for any section of pipeline shall be 2000 gallons per minute.

(7) After the pipeline or section thereof has been filled, it shall be allowed to stand under a slight pressure for at least 48 hours. During this period, bulkheads, valves, and connections shall be examined for leaks. If leaks are found, testing shall be discontinued, and corrective measures satisfactory to the COR shall be taken prior to resumption of the testing.

(8) Apply test pressure as specified in the Piping Schedule and maintain the section under test for a period not less than 4 hours. Check carefully for leaks while test pressure is being maintained.

D. Leakage Testing:

(1) Conduct leakage test for all liquid-conveying pipelines after satisfactory completion of pressure test.

(2) Allow concrete pipelines to remain full of water at least 12 hours prior to starting leakage test.

(3) Maintain test pressure constantly for the minimum test period and accurately measure the amount of water which must be added to maintain the test pressure.

(4) Allowable Leakage Rates (gallons per hour per 1,000 feet per inch diameter):

(a) Ductile Iron Pipe with Push-On or Mechanical Joints: 0.1

(b) Reinforced Concrete Pipe: 1.0

(c) Reinforced Concrete Pressure Pipe: 1.0

(d) Steel Pipe C200: 1.0

(e) Copper, Steel Schedule 40: 0.0

(f) Thermoplastic: 0.0

(g) Pipelines with Welded Joints: 0.0

(5) Leakage Test Procedure:

(a) Examine exposed pipe, joints, fittings and valves. Repair visible leakage or replace the defective pipe, fitting or valve.

(b) Refill the line under test to reach the required test pressure.

(c) Provide a test container filled with a known quantity of water at the start of the test. Attach the test pump suction to the test container.

(d) Pump water from the test container into the line with the test pump to hold the specified test pressure for the test period. Water remaining in the container shall be measured and the amount used during the test shall be recorded on the test report.

(e) Perform all repair, replacement, and retesting required because of failure to meet testing requirements.

E. Vertical Deflection Test for Thermoplastic Pipe: After completion of backfill and at a time compliance-confirmed by COR, the Contractor shall manually pull a pintype vertical gage mounted on a sled through the pipe. Gage shall be set so that if vertical deflection of pipe exceeds 5 percent (5%), it will stop. The Contractor shall excavate and relay all such piping. Gage shall be certified by a compliance-confirmed manufacturer.

F. Prior to making tests, the Contractor shall submit details of his testing procedures with a description of methods and equipment he proposes to use to the COR for compliance-confirmation. The Contractor shall furnish all necessary labor, equipment, water, watertight bulkheads, rodding machine, generator, pumps and all else necessary to carry out the required tests.

3.6 DISPOSAL OF WATER

The Contractor shall provide suitable means for disposal of test and flushing water so that no damage results to facilities or waterways. The means of disposal of test and flushing water shall be subject to the compliance-confirmation of the COR, and approval of applicable local governing authorities and regulatory agencies. All test and flushing water used in all piping systems, other than the storm drain systems, shall be disposed to the SBIWTP's Tank Drain System. The Contractor shall be responsible for any damage caused by the water disposal operations.

3.7 CLEANING AND DISINFECTION

A. Cleaning:

(1) Thoroughly clean all piping and flush prior to placing in service in a manner compliance-confirmed by COR.

(2) Piping 24 inches in diameter and larger shall be inspected from inside and all debris, dirt and foreign matter removed.

(3) If piping which requires disinfection has not been kept clean during storage or installation, the Contractor shall swab each section individually before installation with a five (5%) hypochlorite solution, to ensure clean piping.

B. Disinfection: The Contractor shall perform disinfection procedures conforming to AWWA C651:

(1) Disinfect all potable and fire water piping.

(2) A suggested procedure for accomplishing complete and satisfactory disinfection is specified below. Other procedures will be considered for compliance-confirmation by the COR. Thoroughly flush piping prior to disinfection with water. For pipelines 24 inches in diameter and larger, pipelines shall be manually cleaned, carefully removing all sweepings, dirt and debris prior to disinfection. Continuous feed method of disinfecting shall be used unless alternative method is acceptable to COR.

(3) The Contractor shall provide all water for initial flushing, testing and chlorination. The Contractor shall provide all temporary piping, hose, valves, appurtenances and services required.

(4) Chlorine will be supplied by the Contractor.

(5) Bacteriologic tests will be performed by the Government. A certified test laboratory report will be made available to the Contractor, if requested.

(6) Chlorine concentration in the water entering the piping shall be between 50 and 100 parts per million, such that a minimum residual concentration of 25 milligrams per liter will be left after a 24hour retention period. Care shall be taken to ensure disinfection of the piping in all its parts. The operation shall be repeated as necessary to provide complete disinfection.

(7) After the required retention period, the heavily chlorinated water shall be disposed to the SBIWTP's Tank Drain System.

3.8 IDENTIFICATION OF PIPING

The Contractor shall provide pipe identification markers and arrows, underground warning tape, and pipe detection tape for all buried pipelines in accordance with Specification 40 00 94, Pipe Markers.

3.9 BURIED PIPING SCHEDULE

The following abbreviations are used in the Buried Piping Schedule:

A. Service:

B. Materials:

C. Interior Linings/Exterior Coatings:

D. Schedule or Pressure Class:

E. Joints:

F. Remarks:

G. [x] Refer to notes following Buried Piping Schedule.

SOUTH BAY INTERNATIONAL WASTEWATER…