STANDARD WASTEWATER

SPECIFICATIONS

For

Piedmont MoDOT Maintenance Complex

Wastewater Improvements

MOU Project No. 2023-07-80823

Presented by

Missouri Highways and Transportation Commission

Jefferson City, Missouri

Attention

Refer to MoDOT Facilities Invitation to Bid for additional information and requirements

Prepared by

3213 Southwest Bypass Springfield, MO 65807 417.866.274

Table of Contents

PAGE TO PAGE

33 00 00 UTILITIES

33 01 30 Sewer Acceptance Testing ..........................................................................1:6 33 31 05 PVC Sewer Pipe ...........................................................................................1:4 33 39 13 Manholes .....................................................................................................1:3

Note: Refer to MoDOT standard specifications for all other technical specifications (including but not limited to excavation, trenching, seeding, mulching & others).

Sewer Acceptance Testing 33 01 30 - 1

SECTION 33 01 30

SEWER ACCEPTANCE TESTING

PART 1 GENERAL

1.01 SUMMARY

This section covers the performance testing of the installed sewer, force main, and manholes.

PART 2 PRODUCTS

Not applicable to this section.

PART 3 EXECUTION

3.01 GENERAL REQUIREMENTS

A. The Contractor shall provide at his expense all necessary pumping equipment, testing water, means of conveying test water to the testing site to include piping connections between the piping and the nearest available source of test water, pressure gauges, and other equipment, materials and facilities necessary for the tests.

B. All pipe, fittings, valves, pipe joints and other materials which are found to be defective shall be removed immediately and replaced with new and acceptable material by and at the expense of the Contractor.

3.02 GRAVITY SEWER TESTING

All completed gravity sewers, including plant piping, shall require pneumatic or hydrostatic testing for the purpose of locating potential infiltration and/or exfiltration within the system.

A. Each reach of sewer shall be performance tested and shall meet the requirements of the following performance tests. It shall be the responsibility of the Contractor to notify the Engineer and City personnel at least 24 hours in advance of the time and place at which testing work will be done. All defects shall be repaired to the satisfaction of the Engineer and the City.

B. Lamping: Each straight section of sewer between manholes shall be straight and uniformly graded. Each such section will be lamped by the Contractor in the presence of the Engineer.

C. Vertical Deflection: Initial installed vertical deflection for flexible pipe (PVC sewer pipe) shall not exceed 5 percent. The Contractor shall test the initial installed vertical deflection by pulling a mandrel or other device through all reaches of sewer to demonstrate that the 5 percent deflection limitation has not been exceeded. The deflection testing shall not be performed until a minimum of 30 days after backfilling of pipe. The method of test shall be acceptable to the Engineer. The Contractor shall submit all deflection test

33 01 30 - 2 results to the Engineer.

D. Pneumatic Testing Procedure: The Contractor shall perform low pressure air testing on all sections of completed sewer 8-inch through and including 24~inch diameters, in the presence of the Engineer. It will be the responsibility of the Contractor to furnish and operate equipment capable of making the required tests. Pneumatic plugs shall be utilized to isolate sewer sections for testing. Plugs shall have a sealing length equal to or greater than the diameter of the pipe to be inspected. Pneumatic plugs shall resist internal test pressure without requiring external bracing or blocking. All air used shall pass through a single control panel and three individual hoses shall be used for connections from the control panel to 1) pneumatic plugs for inflation; 2) sealed line for introducing the low pressure air; and 3) to the sealed line for continually monitoring the air pressure rise in the sealed line. Equipment shall be Cherne Air-Lac equipment or approved equal. Testing methods and air leakage rates shall conform to ASTM C828, latest revision, as a minimum.

Otherwise, the following procedures shall be followed:

1. Pipe Testing:

a. Pipe Above Groundwater Table: All pneumatic plugs shall be seal-tested before being used in the actual test installation. One length of pipe shall be laid on the ground and sealed at both ends with the pneumatic plugs to be checked. Air shall be introduced into the plugs to 25 psig. The sealed pipe shall be pressurized to 5 psig. The plugs shall hold against this pressure without bracing and without movement of the plugs of the pipe. After a manhole to manhole reach of pipe has been backfilled and cleaned and the pneumatic plugs are checked by the above procedure, the plugs shall be placed in the line at each manhole and inflated to 25 psig. Low pressure air shall be introduced into this sealed line until the internal air pressure reaches 4 psig greater than the average back pressure of any groundwater that may be over the pipe. At least two minutes shall be allowed for the air pressure to stabilize. After the stabilization period (3.5 psig minimum pressure in the pipe), the air hose from the control panel to the air supply shall be disconnected. The portion of line being tested shall be termed "Acceptable" if the time required in minutes for the pressure to decrease from 3.5 to 2.5 psig shall not be less than the time shown for the given diameters in the following table:

Pipe Diameter in

Inches

Minimum Time

(Min.:Sec.)

Max. Length (ft.) for Min.

Time

Time (sec.) for Longer Length

(L)

4 3:46 597 0.380 L 6 5:40 398 0.854 L 8 7:34 298 1.520 L 10 9:26 239 2.374 L 12 11:20 199 3:418 L 15 14:10 159 5:342 L 18 17:00 133 7.692 L 21 19:50 114 10.470 L

33 01 30 - 3

24 22:40 99 13.674 L 27 25:30 88 17.306 L 30 28:20 80 21.366 L 33 31:10 72 0.380 L 36 34:00 66 0.854 L

b. Pipe Below Groundwater Table: In areas where groundwater is known to exist, the Contractor shall install a one-half inch diameter capped pipe nipple, approximately 10" long, through the manhole wall on top of one of the sewer lines entering the manhole. This shall be done at the time the sewer line is installed. Immediately prior to the performance of the test, the groundwater shall be determined by removing the pipe cap, blowing air through the pipe nipple into the ground so as to clear it, and then connecting a clear plastic tube to the nipple. The hose shall be held vertically and a measurement of the height in feet of water over the invert of the pipe shall be taken after the water has stopped rising in this plastic tube. The height in feet shall be divided by 2.3 to establish the pounds of pressure that will be added to all readings. (For example, if the height of water is 11-1/2 feet, then the added pressure will be 5 psig. This increases the 3.5 psig to 8.5 psig, and the 2.5 psig to 7.5 psig. The allowable drop of one pound and the timing remain the same.)

2. Hydrostatic Testing Procedures: The Contractor shall be required to make hydrostatic infiltration/exfiltration tests of all sewer lines 30~inches in diameter or greater. Manholes on these lines shall be hydrostatically tested at the same time. Said testing shall be performed in the presence of the Engineer to demonstrate that all lines and manholes are free of leaks. All piping shall be tested. Tests may be made as each manhole to manhole section is completed or after the entire line is completed. In any event, satisfactory test results must be obtained before the manhole, the line or any part thereof will be accepted.

a. Plant Piping: A 112-inch diameter galvanized nipple shall be cast into the wall of each manhole and capped on the inside. At the time of testing, a clear plastic hose shall be attached to the pipe nipple in the upstream manhole of the section to be tested to serve as a sight glass in recording the groundwater level. Test plugs shall be placed in the end of each sewer pipe on the upstream side of both manholes and inflated to a maximum pressure of 16 psig. Plugs shall be thoroughly blocked to prevent them from blowing out. The sewer pipe and upstream manhole shall be filled with potable water, or clean non-potable water, to a level 4-112 feet above groundwater or 7 feet above the pipe invert, whichever is higher. Ten minutes shall then be allowed for absorption, after which the water level shall be brought back to the test elevation. The specified head shall be maintained on the pipe for a period of eight hours. Sufficient water shall be added to maintain this level. All water added shall be metered to within one-tenth of a gallon and recorded. The maximum allowable leakage shall be as specified herein. The Contractor shall provide all water pumping facilities, and metering equipment necessary to perform the test. After a section is tested, all water shall be pumped out by the Contractor.

33 01 30 - 4

3. Manholes: All manholes on lines 24-inches in diameter or smaller shall be vacuum tested. Vacuum testing, performed in accordance with this specification, shall be allowed as a substitute for hydrostatic testing of manholes. The vacuum test equipment shall be approved by the Engineer prior to commencing manhole testing.

a. The vacuum "test head" assembly shall be placed inside the frame of the manhole cover, in order to include in the test the seal between the frame and the manhole cone section, slab, or adjusting rings.

b. Plugs shall be placed at least eight inches inside all pipes entering the manhole. Location of plugs shall be such that when inflated, they are past the gasket seal or joint of the manhole and sewer pipe. All plugs shall be braced sufficiently to prevent the plug or pipe from becoming dislodged and drawn into the manhole.

c. A vacuum of at least 10-112 inches mercury shall be drawn on the manhole. The valve on the vacuum line to the manhole shall be closed, and the vacuum line disconnected. The vacuum within the manhole shall then be adjusted to 10 inches to mercury by opening the vacuum line valve.

d. A liquid-filled pressure gauge having a face of 3-112 inches and reading from zero to 30 inches of mercury shall be utilized.

e. The time for the vacuum reading to drop from 10 inches of mercury to 9 inches of mercury must be equal to or less than the following values in order for the manhole to be considered as passing the vacuum test.

Manhole Diameter Time (seconds) 48-inch 120 60~inch 150 72-inch 180 96-inch 210

f. If vacuum drops less than one inch mercury within the test time, the manhole is considered acceptable and passes the test. If manhole fails and leaks, the contractor shall make the needed repairs and test again until satisfactory results are obtained. Test may be done before backfilling, but shall be repeated after backfill.

g. All safety procedures, placing of plugs, and bracing, labor, and other work required for testing will be the responsibility of the contractor.

h. The contractor shall supply all required test plugs, vacuum plate, and vacuum pump.

4. Infiltration/Exfiltration Allowance: Infiltration or exfiltration for sewers 8-inch through 24-inch diameter shall not exceed 200 gallons per inch of pipe diameter per mile per day for any section of sewer. Infiltration or exfiltration for sewers greater than 24-inch diameter shall not exceed 6000 gallons per day per mile of pipe. Infiltration or exfiltration for manholes shall not exceed 1.14 gallons per day per vertical foot of manhole.

5. Infiltration/Exfiltration Elimination: The Contractor shall locate all sources of infiltration and exfiltration in the sewer lines, manholes, and appurtenances, and shall correct deficiencies and eliminate infiltration/exfiltration sources in a manner approved by the Engineer. All sections of sewer line, manholes, and appurtenances shall be re-tested

33 01 30 - 5 after corrections are finalized. The Contractor shall carry the sole responsibility for providing a sewer system having infiltration or exfiltration below the specified limits.

3.03 PRESSURE SEWER TESTING

A. Testing: Installed pressure sewer lines shall be hydrostatically tested as follows. Testing shall include both a "pressure test" of at least two hours duration for the purpose of blowing defective joints, and a "leakage test" to determine actual loss of water from the system. The use of compressed air for testing pipe will not be permitted. Contractor shall be responsible for adequately plugging and bracing, as necessary, the ends of the pressure sewer, whether they be at the lift station or at the discharge location, to allow the for hydrostatic testing.

1. Pressure Test: After the pipe has been laid, all newly lain pipe shall be subjected to a hydrostatic pressure of at least 100 psi at the lowest point in the system.

a. Test Pressure Restrictions: Test pressures shall be

(1) of at least 2-hour duration;

(2) not vary by more than ±5 psi;

(3) not exceed twice the rated pressure of the valves or hydrants when the pressure boundary of the test section includes closed gate valves or hydrants.

b. Pressurization: Each valve or isolated section of pipe shall be filled with water slowly and the specified test pressure, based on the elevation of the lowest point of the line or section under test and corrected to the elevation of the test gauge, shall be applied by means of a pump connected to the pipe in a manner satisfactory to the Owner.

c. Air Removal: Before applying the specified test pressure, air shall be expelled completely from the pipe. After all the air has been expelled, the test pressure shall be applied.

d. Examination: All exposed pipe, fittings, valves, and joints shall be examined fully during the test. Any damaged or defective pipe, fittings, valves, or hydrants that are discovered following the pressure test shall be repaired or replaced with sound material and the test shall be repeated until it is satisfactory to the Owner.

2. Leakage Test: A leakage test shall be conducted concurrent with the pressure test.

a. Leakage Defined: Leakage shall be defined as the quantity of water that must be supplied into the new laid pipe, or any valved section thereof, to maintain pressure within 5 psi of the specified test pressure after the air in the pipeline has been expelled and the pipe has been filled with water.

b. Allowable Leakage: No pipe installation will be accepted if the leakage is greater than that determined by the following formula:

L =

In which

33 01 30 - 6

L is the allowable leakage in gallons per hour;

N is the number of joints in the length of pipeline tested;

D is the nominal diameter of the pipe in inches; and P is the average test pressure during the leakage test, in pounds per square inch gauge.

When testing against closed metal-seated valves, an additional leakage per closed valve of 0.0078 gal/hr/in of nominal valve size shall be allowed.

c. Acceptance of Installation: Acceptance shall be determined on the basis of allowable leakage. If any test of pipe laid discloses leakage greater than that specified above, the Contractor shall, at his own expense, locate and repair the defective material until the leakage is within the specified allowance. All visible leakages are to be repaired regardless of the amount of leakage.

3.04 MISCELLENEOUS

A. All testing work shall be done in the presence of the Engineer. The Contractor shall notify the Engineer at least three days in advance of the times and places at which testing work is to be done.

B. It is the intent of these specifications that all joints in piping shall be watertight and free from visible leaks during the prescribed leakage test and each and every leak which may be discovered at any time prior to the expiration of one year from and after the date of final acceptance of the work by the Owner shall be located and repaired by and at the expense of the Contractor, regardless of any amount that the total line leakage rate during the specified leakage test may be below the specified maximum rate.

END OF SECTION

PVC Sewer Pipe 33 31 05 - 1

SECTION 33 31 05

PVC SEWER PIPE

A. This section covers Polyvinyl Chloride Piping (PVC). PVC pipe shall be furnished complete with all fittings, jointing materials, anchors, blocking, encasement, and other necessary appurtenances.

PART 2 PRODUCTS

2.01 MATERIALS

A. PVC pipe and fittings 4" through 15" shall meet or exceed the requirements of the latest revision of ASTM D-3034 and shall be cell classification of 12454-B, 12454-C or 13364-B as defined in ASTM D 1784.

B. Pipe and fittings 18" through 27" shall meet ASTM F-679 and shall be cell classification of 12364-C or 12454-C.

C. Minimum pipe stiffness (F/Y) at 5ø deflection shall be 46 for all sizes when tested in accordance with ASTM D2412.

D. All Joints of pipe and fittings shall have elastomeric gaskets and shall show no signs of leakage when tested in accordance with D 3212. Solvent weld joints will not be permitted below grade.

SIZES O.D. DIMENSIONS WALL THICKNESS

4" 4.215 .125 inches 6" 6.275 .180 inches 8 " 8.400 .240 inches 10" 10.500 .300 inches 12" 12.500 .360 inches 15" 15.300 .414 inches

18" (T-1) 18.700 .536 inches 21" (T-1) 22.047 .632 inches 24" (T-1) 24.803 .711 inches 27" (T-1) 27.953 .801 inches

PART 3 EXECUTION

3.01 GENERAL REQUIREMENTS

A. For residential lots, where applicable. All service wyes or tee fittings will be located in the center of each lot for ease of location on future hookups. All service lateral lines shall be schedule 40 meeting the requirements of ASTM D2665 or D2441.

33 31 05 - 2

B. All sewer lines at a bury depth of over 12'0" will be SDR-21\Class 200 PVC pipe meeting the requirements of ASTM D2241 or C-900 PVC when designated. All other pipes shall be SDR 35 or as designated on the construction plans. Any adaptation from SDR sizes shall be completed with a suitable adapter.

3.02 HANDLING

A. Pipe, fittings, and accessories shall be handled in a manner that will insure installation in sound, undamaged condition. Equipment, tools, and methods used in unloading, reloading, hauling and laying pipe and fittings shall be such that the pipe and fittings are not damaged. Hooks inserted in ends of pipe shall have broad, well-padded contact surfaces.

3.03 CUTTING PIPE

A. Cutting shall be done in a neat manner, without damage to the pipe. Cuts shall be smooth, straight, and at right angles to the pipe axis. After cutting, the end of the pipe shall be dressed with a file to remove all roughness and sharp corners.

3.04 CLEANING

A. The interior of all pipe and fittings shall be thoroughly cleaned of foreign matter before being installed and shall be kept clean until the work has been accepted. Before jointing, all contact surfaces shall be wire brushed, if necessary, wiped clean, and kept clean until jointing is completed.

B. Every precaution shall be taken to prevent foreign material from entering the pipe during installation. No debris, tools, clothing, or other materials shall be placed in the pipe.

3.05 INSPECTION

A. Pipe fittings shall be carefully examined for cracks and other defects immediately before installation. Spigot ends shall be examined with particular care since they are vulnerable to damage from handling. All defective pipe and fittings shall be removed from the site of the work.

3.06 ALIGNMENT

A. Pipelines or runs intended to be straight shall be laid straight.

3.07 LAYING PIPE

A. Pipe shall be protected from lateral displacement by placing the specified pipe embedment material. Under no circumstances shall pipe be laid in water and no pipe shall be laid under unsuitable weather or trench conditions.

3.08 PUSH-ON-JOINTS

A. All instructions and recommendations of the pipe manufacturer, relative to gasket installation and other jointing operations shall be followed by the Contractor. All joint surfaces shall be lubricated with heavy vegetable soap

33 31 05 - 3 solution immediately before the joint is completed.

3.09 RELATION TO WATER MAINS

3.09.1 Horizontal Separation

A. Sewer mains shall be laid at least 10 feet (3.0 m) horizontally from any existing or proposed water main. The distances shall be measured edge to edge. In cases where it is not practical to maintain a 10-foot separation, the City may allow deviation on a case-by-case basis, if supported by data from the design engineer. Such deviations may allow installation of the sewer closer to a water main, provided that the water main is in a separate trench or on an undisturbed earth shelf located on one side of the sewer at such an elevation that the bottom of the water main is at least 18 inches (46 cm) above the top of the sewer.

3.09.2 Crossings

A. Sewers crossing water mains shall be laid to provide a minimum of vertical distance of 18 inches (46 cm) between the outside of the water main and the outside of the sewer. This shall be the case where the water main is either above or below the sewer. The crossing shall be arranged so that the sewer joints will be equal distance and as far as possible from the water main joints.

Where a water main crosses under a sewer, adequate structural support shall be provided for the sewer to prevent damage to the water main.

3.09.3 Special Conditions

A. When it is impossible to obtain proper horizontal and vertical separation as stipulated above, the sewer shall be designed and constructed equal to water pipe, and shall be pressure tested to assure water tightness prior to backfilling.

3.10 STREET CROSSING

A. No cutting of concrete/asphalt surfaces shall be allowed unless prior City approval is obtained in writing. At all locations where sewer lines are placed within the street, sewer trench shall be backfilled with 3/4" crushed limestone to the subgrade of the proposed pavement. Creek gravel or similar material will not be allowed.

3.11 MARKING

A. Each pipe and fitting shall have plainly and permanently marked thereon:

1. Manufacturer's name or trademark.

2. Nominal pipe size.

3. ASTM Designation D3034 and Class Number

4. SDR number.

5. Material designation.

33 31 05 - 4

3.12 ACCEPTANCE TESTS

A. Each reach of sewer shall meet the requirements of Section 33 01 30 -

SEWER ACCEPTANCE TESTING.

Manholes 33 39 13 - 1

SECTION 33 39 13

MANHOLES

A. This section covers standard, drop, and wet well manholes. Manholes shall be constructed complete with covers, steps, fittings, and other appurtenances, in accordance with the details shown on the drawings.

B. At the option of the Contractor, manholes shall be constructed of precast concrete sections or cast-in-place concrete.

C. Only manholes which are required to have outside pipe and fittings for dropping sewage into the lower line will be designated as drop manholes.

PART 2 PRODUCTS

2.01 MATERIALS

A. Structural Cast-in-Place Materials

1. Portland Cement: ASTM C150, Type II

2. Concrete: ASTM C94 with compressive strength of 4000 psi at 28 days. Curing and protection in accordance with Section 03 30 00 - Cast-in-Place Concrete

3. Brick: ASTM C32, Grade MS or ASTM C62, Grade SW

4. Granular Backfill: See bedding requirements Section 31 23 16 - Excavation and Trenching

B. Precast Sections

1. Standard and Drop Manhole:

Circular precast concrete; ASTM C478 except as modified

2. Wet well Manhole: Reinforced concrete pipe; ASTM C76, Class II, Wall B

3. Minimum Thickness: As indicated on drawings

4. Openings: Circular shaped block out for each connecting pipe, with A-Lock locking-type gaskets installed by manhole manufacturer

5. Hydrated Lime: ASTM C207, Type S

6. Sand: Concrete sand, fine aggregate, sieved through 8 mesh screen

7. Shrinkage-Correcting Aggregate:

Master Builders "Embeco", Sika "Kemox" or Sonneborn "Ferrolith G-DS", or equal

33 39 13 - 2

8. Mortar One part Portland cement, 1/2 part hydrated lime, 3 parts sand

9. Non-shrinking Mortar Premixed or job mixed; job mixed shall be one part shrinkage-correcting aggregate, one part Portland cement, and one part sand.

C. Gaskets

1. Mastic: Fed Spec SS-S-210; K.T. Snyder "Ram-Nek", or equal

2. Rubber: Neoprene or other synthetic, 40 plus or minus 5 hardness when measured by ASTM D2240, Type A durometer

3. Rubber Joint Filler: Natural or synthetic

4. Hardness: 40 plus or minus 5 when measured by ASTM D2240, Type A durometer

5. Tensile Strength: 1200 psi minimum

6. Coal Tar Paint: Koppers "Bitumastic Super-Service Black", Porter "Tarmastic 103", Tnemec "46-449, Heavy Duty Black", or equal

D. Manhole Steps:

1. Cast Iron: ASTM A48, with asphalt varnish coating applied at the foundry

2. Composition: Plastic ASTM 2146 Type II, Grade16906.

Steel reinforcing bar ASTM A615

3. Manhole Frame and Covers:

ASTM A48, with asphalt varnish coating applied at the foundry. Frame and Cover shall be equal to a Neenah R-1770-A

PART 3 EXECUTION

3.01 DELIVERY

A. Precast concrete sections shall not be delivered to the job until representative concrete control cylinders have attained a strength of at least 80% of the specified minimum.

3.02 INSPECTION

A. Precast concrete sections and brick shall be inspected when delivered and all cracked or otherwise visibly defective units rejected.

3.03 CONSTRUCTION

A. All mortar shall be used within 40 minutes after mixing. Mortar which has begun to take on initial set shall be discarded and not be mixed with additional cement or new mortar.

33 39 13 - 3

B. In no case shall the invert section through a manhole be greater than that of the outgoing pipe. The shape of the invert shall conform exactly to the lower half of the pipe it connects. Side branches shall be connected with as large radius of curve as practicable. All inverts shall be troweled to a smooth clean surface.

C. Circular precast sections shall be provided with a rubber or mastic gasket to seal joints between sections. The space between connecting pipes and the wall of precast sections shall be equipped with A-Lock Locking-type gaskets or equal to be installed at the factory.

3.04 WATERPROOFING

A. Manholes shall be waterproofed by application of heavy duty coal tar coating applied over entire exterior surface to attain a dry film thickness of not less than 15 mils. Surface to receive coating shall be thoroughly dry.

3.05 FRAMES AND COVERS

A. Frames shall be set so that the top of the cover is flush with finished pavement or two inches higher than finish grade in unpaved areas except where noted otherwise on the drawings.

3.06 PIPE CONNECTIONS

A. Pipe connections shall be such that differential settlement between pipe and manholes is permitted and shall be made using waterstops, A-Lok gaskets, standard O-ring gaskets, special manhole couplings, or other methods as approved.

3.07 STUBS

A. Future connections shall be provided in manholes at the locations shown on the drawings. Stubs shall be not less than 3'-0" or more than 4'-0" long and shall terminate in a bell plug.

3.08 HOLES

A. Core holes and handling holes shall be repaired by cementing a properly shaped concrete plug in place with epoxy cement or by other methods acceptable to the Engineer.

3.09 PAINTING

A. If castings arrive on the job without a foundry coating, one coat of coal tar paint shall be applied. Before painting all castings shall be thoroughly cleaned and properly supported. All loose rust shall be removed by wire brushing.

Castings shall not be handled until the paint is dry and hard.