SECT-45_WASTEWATER_FORCE_MAINS.DOC

SECTION 45 - WASTEWATER FORCE MAINS

Item No. Title

SECTION 45 - WASTEWATER FORCE MAINS

45.1 GENERAL

45.2 PIPE INSPECTION AND TEST

45.5 PIPE HANDLING

45.7 NOTIFICATION AND CONNECTION TO EXISTING MAINS

45.9 VALVE BOXES

45.10 SEPARATION OF FORCE MAINS AND WATER MAINS

45.11 FORCE MAIN CONSTRUCTION

45.12 HYDROSTATIC TESTS

45.13 FINAL CLEANING

45.14 LOCATION AND IDENTIFICATION

45.1 GENERAL

These specifications cover the pipe, fittings, and accessory items used for wastewater force main systems.

Pipe used in wastewater force main systems shall be either Polyvinyl Chloride (C900 DR18 PVC), or Ductile Iron Pipe (DIP) – minimum Pressure Class 150.

The CONTRACTOR shall be responsible for all materials furnished and storage of same, until the date of project completion. He shall replace at his expense all materials found to be defective or damaged in handling or storage. The CONTRACTOR shall, if requested by the CITY ENGINEER or designee, furnish certificates, affidavits of compliance, test reports, or samples for check analysis for any of the materials specified herein. All pipe delivered to project site for installation is subject to random testing for compliance with the designated specifications.

45.2 PIPE INSPECTION AND TEST

Each length of pipe shall bear the name or trademark of the manufacturer, the location of the manufacturing plant, and the class or strength classification of the pipe. The markings shall be plainly visible on the pipe barrel. Pipe, which is not marked, clearly is subject to rejection. All rejected pipe shall be promptly removed from the project site by the CONTRACTOR.

All pipe and accessories to be installed under this Contract shall be inspected and tested at the place of manufacture by the manufacturer as required by the Standard Specifications to which the material is manufactured.

Each length of pipe shall be subject to inspection and approval at the factory, point of delivery, and site of work. If requested by the CITY ENGINEER or designee, a sample of pipe to be tested shall be selected at random by the CITY or the testing laboratory hired by the CITY.

When the specimens tested conform to applicable standards, all pipe represented by such specimens shall be considered acceptable based on the test parameters measured. Copies of test reports shall be available before the pipe is installed in the project.

In the event that any of the test specimens fail to meet the applicable standards, all pipe represented by such tests shall be subjected to rejection. The CONTRACTOR may furnish two additional test specimens from the same shipment or delivery, for each specimen that failed and the pipe will be considered acceptable if all of these additional specimens meet the requirements of the applicable standards. All such retesting shall be at the CONTRACTOR'S expense.

45.3 PVC PIPE

45.3.1 PVC PIPE

All PVC pipe shall be manufactured in accordance with AWWA Standard C900, latest edition. PVC pipe shall have a minimum working pressure rating of 150 psi and shall have a dimension ratio (DR) of 18. Pipe shall be the same OD as ductile iron pipe.

45.3.2 JOINTS

PVC pipe shall have integral bell push on type joints conforming to ASTM D3139.

45.3.3 FITTINGS

Fittings used with PVC pipe shall conform to Section 45.4

45.4 DUCTILE IRON PIPE AND FITTINGS

45.4.1 DUCTILE IRON PIPE

All ductile iron pipe of nominal diameter four (4) through fifty four (54) inches shall conform to ANSI/AWWA A21.51/C151. A minimum of Pressure Class 150 pipe shall be supplied for all sizes of pipe, unless specifically called out in the DRAWINGS or required by the CITY ENGINEER or designee.

45.4.2 FITTINGS

All fittings shall be mechanical joint ductile iron or gray iron conforming to ANSI/AWWA A21.10/C110, 250 psi minimum pressure rating.

45.4.3 JOINTS

Joints for ductile iron pipe and fittings shall be push-on or mechanical joints conforming to ANSI/AWWA A21.11/C111, unless otherwise called for on the DRAWINGS. Where called for on the Drawings, restrained or flanged joints shall be provided. Flanged joints shall conform to ANSI Standard B16.1-125 LB. Restrained joints shall conform to Sections 34.3 or 34.4.

45.4.4 COATINGS AND LININGS

Where ductile iron pipe and fittings are to be below ground or installed in a casing pipe the coating shall be a minimum 1.0 mil thick in accordance with ANSI/AWWA A21.51/C151. Where ductile iron pipe and fittings are to be installed above ground, pipe, fittings and valves shall be thoroughly cleaned and given one field coat (minimum 1.5 mils dry thickness) of rush inhibitor primer. Intermediate and finished field coats of Alkyd shall also be applied by the CONTRACTOR (minimum 1.5 mils dry thickness each coat).

Primer and field coats shall be compatible and shall be applied in accordance with the manufacturers recommendations. Final field coat color shall be green for raw wastewater.

All ductile iron pipe and fittings shall have an interior protective lining of Protecto 401, Permite or approved equal with a minimum dry thickness of 40 mils applied by the pipe manufacturer.

45.4.5 POLYETHYLENE ENCASEMENT

The pipe shall be polyethylene encased (8 mil) where shown on the DRAWINGS or required by the CITY ENGINEER or designee in accordance with ANSI/AWWA A21.51/C105.

45.5 PIPE HANDLING

Requirements specified in Section 51.2 shall apply.

45.6 AIR AND VACUUM RELEASE VALVES

45.6.1 GENERAL

Wastewater force mains shall be equipped with air vacuum release valves located as shown on the DRAWINGS. Valves shall be located in an enclosure as detailed on the STANDARD DRAWINGS.

The valves shall be as described below.

45.6.2 AUTOMATIC WASTEWATER AIR/VACUUM VALVE

The valve body shall be of cast iron ASTM A126-B; the floats, float guide and stem shall be of stainless steel Type 304. Valves shall have upper and lower floats; needle openings are not acceptable. The resilient seat shall be of BUNA N. The valve shall be suitable for 150 psi working pressure. The valve shall have standard two (2) inch NST inlets and outlet ports unless otherwise shown on the DRAWINGS. Provide back-flushing accessories. Provisions shall be made for back-flushing the valve with clean water.

45.7 NOTIFICATION AND CONNECTION TO EXISTING MAINS

Pressure connection to existing wastewater force mains shall comply with the requirements of Section 35.3.

45.8 RESILIENT WEDGE GATE VALVES

45.8.1 GENERAL

All gate valves twenty inches (20") and smaller shall be resilient wedge gate valves. Such valves shall be resilient wedge, manufactured to meet or exceed the requirements of AWWA C509, latest revision, and in accordance with the following specifications. Valves shall have an unobstructed waterway equal to or greater than the full nominal diameter of the valve.

45.8.2 MATERIAL

The valve body, bonnet, and bonnet cover shall be cast iron ASTM A126, Class B. All ferrous surface inside and outside shall have a fusion-bonded epoxy coating. A two-inch (2") wrench nut shall be provided for operating the valve. All valves are to be tested in strict accordance with AWWA C 509.

45.8.3 MISCELLANEOUS REQUIREMENTS

The valves shall be non-rising stem with the stem made of cast, forged, or rolled bronze as specified in AWWA C509.

Two stem seals shall be provided and shall be of the O-ring type. The stem nut must be independent of the gate.

The resilient sealing mechanism shall provide zero leakage at the water working pressure when installed with the line flow in either director.

45.9 VALVE BOXES

Requirements specified in Section 52.5 shall apply, except that covers shall have "sewer" cast into the top.

45.10 SEPARATION OF FORCE MAINS AND WATER MAINS

Requirements specified in Section 51.3 shall apply.

45.11 FORCE MAIN CONSTRUCTION

Requirements specified in Section 51.4 shall apply.

45.12 HYDROSTATIC TESTS

Requirements specified in Section 51.5 shall apply except that all pipe sections to be tested shall be subjected to a hydrostatic pressure of 100 psi for 2 hours.

FINAL CLEANING

Prior to final inspection and acceptance of the force main by the CITY, CONTRACTOR shall flush and clean all parts of the system. Flushing and cleaning shall remove all accumulated construction debris, rocks, gravel, sand, silt, and other foreign material from the sewer system at or near the downstream end.

Upon the CITY ENGINEER'S or designee's final inspection of the pressure pipe systems, if any foreign matter is still present in the system, CONTRACTOR shall clean the sections and portions of the lines as required.

45.14 LOCATION AND IDENTIFICATION

All force mains shall be installed with a continuous, three inch (3") wide metallic locator tape with the words "CAUTION BURIED FORCE MAIN BELOW," imprinted at one foot (1') intervals, installed eighteen inches (18") above and centered over the top of the pipe for location purposes. A continuous, solid 12 CU.UF 1 AWG tracer wire with a green covering shall be attached to the main. All wire splices shall be completed using a splice kit and wire nut. Splice kit shall have a durable plastic housing with water resistant silicone gel. See STANDARD DRAWINGS. (Ranger Serviseal Closure with Poly-Bee sealant or approved equal.)

All PVC force mains shall be solid green color with black lettering. All lettering shall appear legibly on pipe and shall run the entire length of the pipe. Lettering shall read as is acceptable for the intended use.

All ductile iron force mains shall be marked with a continuous stripe located within the top 90 degrees of the pipe. Said stripe shall be a minimum of two inches (2") in width and shall be green in color (factory painted stripe).