Section_33_40_00_Storm_Drainage_Utilities.pdf

SECTION 33 40 00

STORM DRAINAGE UTILITIES

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 within the text by the basic designation only.

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION

OFFICIALS (AASHTO)

AASHTO HB-17 (2002; Errata 2003; Errata 2005, 17th

Edition) Standard Specifications for Highway Bridges

AMERICAN CONCRETE INSTITUTE INTERNATIONAL (ACI)

ACI 346 (2009) Specification for Cast-in-Place Concrete Pipe

INTERNATIONAL (ASTM)

ASTM C1103 (2014) Standard Practice for Joint Acceptance

Testing of Installed Precast Concrete Pipe Sewer Lines

ASTM C1103M (2014) Standard Practice for Joint Acceptance

Testing of Installed Precast Concrete Pipe Sewer Lines (Metric)

ASTM C14 (2015) Standard Specification for Concrete Sewer, Storm Drain, and Culvert Pipe

ASTM C1433 (2016b) Standard Specification for Precast Reinforced Concrete Monolithic Box Sections for Culverts, Storm Drains, and Sewers

ASTM C1433M (2016b) Standard Specification for Precast Reinforced

Concrete Monolithic Box Sections for Culverts, Storm Drains, and Sewers (Metric)

ASTM C14M (2014) Standard Specification for Concrete Sewer, Storm Drain, and Culvert Pipe (Metric)

ASTM C231/C231M (2017a) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

ASTM C270 (2014a) Standard Specification for Mortar for Unit

Masonry

ASTM C443 (2012; R 2017) Standard Specification for Joints for Concrete Pipe and Manholes, Using Rubber Gaskets

ASTM C443M (2012; R 2017) Standard Specification for Joints for

Concrete Pipe and Manholes, Using Rubber Gaskets (Metric)

ASTM C444 (2017) Standard Specification for Perforated

Concrete Pipe

ASTM C444M (2017) Standard Specification for Perforated Concrete Pipe (Metric)

ASTM C655 (2014) Reinforced Concrete D-Load Culvert, Storm

Drain, and Sewer Pipe

ASTM C76 (2015) Standard Specification for Reinforced Concrete Culvert, Storm Drain, and Sewer Pipe

ASTM C76M (2014) Standard Specification for Reinforced Concrete

Culvert, Storm Drain, and Sewer Pipe (Metric)

ASTM C877 (2008) External Sealing Bands for Concrete Pipe, Manholes, and Precast Box Sections

ASTM C877M (2002; R 2009) External Sealing Bands for Concrete

Pipe, Manholes, and Precast Box Sections (Metric)

ASTM C969 (2017) Standard Practice for Infiltration and Exfiltration Acceptance Testing of Installed Precast Concrete Pipe Sewer Lines

ASTM C969M (2017) Standard Practice for Infiltration and Exfiltration

Acceptance Testing of Installed Precast Concrete Pipe Sewer Lines (Metric)

ASTM C990 (2009; R 2014) Standard Specification for Joints for

Concrete Pipe, Manholes and Precast Box Sections Using Preformed Flexible Joint Sealants

ASTM D1056 (2014) Standard Specification for Flexible Cellular

Materials - Sponge or Expanded Rubber

ASTM D1171 (2016; E 2016) Standard Test Method for Rubber Deterioration - Surface Ozone Cracking Outdoors (Triangular Specimens)

ASTM D1557 (2012; E 2015) Standard Test Methods for

Laboratory Compaction Characteristics of Soil Using

Modified Effort (56,000 ft-lbf/ft3) (2700 kN-m/m3)

ASTM D1751 (2004; E 2013; R 2013) Standard

Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)

ASTM D6938 (2017) Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth)

1.2 SUBMITTALS

Submit the following in accordance with submittal procedures in the scope of work.

A. Product data and shop drawings of culverts, concrete, rebar, headwall with parapet, apron, wingwalls and water bar

B. Certificates: Resin;

Certification Oil Resistant

Gasket Leakage Test

Hydrostatic Test on Watertight Joints

Determination of Density

Frame and Cover for Gratings

Post-Installation Inspection Report

C. Manufacturer's Instructions

Placing Pipe

1.3 DELIVERY, STORAGE, AND HANDLING

1.3.1 Delivery and Storage

Materials delivered to site shall be inspected for damage, unloaded, and stored with a minimum of handling. Materials shall not be stored directly on the ground. The inside of pipes and fittings shall be kept free of dirt and debris. Before, during, and after installation, plastic pipe and fittings shall be protected from any environment that would result in damage or deterioration to the material. Keep a copy of the manufacturer's instructions available at the construction site at all times and follow these instructions unless directed otherwise by the COR. Solvents, solvent compounds, lubricants, elastomeric gaskets, and any similar materials required to install plastic pipe shall be stored in accordance with the manufacturer's recommendations and shall be discarded if the storage period exceeds the recommended shelf life. Solvents in use shall be discarded when the recommended pot life is exceeded.

1.3.2 Handling

Materials shall be handled in a manner that ensures delivery to the trench in sound, undamaged condition. Pipe shall be carried to the trench, not dragged.

PART 2 PRODUCTS

2.1 CONCRETE BOX CULVERTS (CBC)

Workmanship and materials shall conform to New Mexico Department of Transportation’s (NMDOT) Standard Specifications for Highway and Bridge Construction, 2014 edition, and applicable supplemental specifications and special provisions.

2.1.1 Concrete shall be Class AA, chamfer all edges on concrete ¾”.

2.1.2 Reinforcing bars shall conform to requirements of AASHTO M31. Reinforcing bars shall be grade 60. Minimum splice length shall be 2’ on all #4 bars, and 2’-6” on all #5 bars.

Longitudinal splices should be staggered by a minimum of two times the splices length in adjacent bars. No splices shall be allowed in vertical bars except as shown on drawings.

Splices shall not be allowed in transverse direction.

2.1.3 Manufactured in accordance with and conforming to NMDOT Standard Drawing 511-59-1/2 and 2/2 for normal and two triple barrel CBC.

2.1.4 Precast reinforced concrete box shall be manufactured in accordance with and conforming to ASTM C1433.

2.2 DRAINAGE STRUCTURES

2.2.1 Headwalls, wingwalls, footing and apron

The concrete box culverts shall include headwall, wingwalls, wingwall footing and apron as per NMDOT Standard Drawings series 511.

2.2.2 Parapet

The headwall shall include a 36” high parapet, 6” thick with ¾” chamfer edge; and reinforced with #5 rebar @ 8” o.c.e.w. Pour monolithic with headwall and construction joints every 8 feet in length.

2.2.3 Water Bar

Build an 18” high, 12” thick concrete water bar pour monolithic with the concrete apron on the inlet of the CBC, reinforced.

2.2.4 Riprap Rundown

Construct flume as per NMDOT Standard Drawing 511-05-4/4, type III.

2.3 MISCELLANEOUS MATERIALS

2.3.1 Concrete

Unless otherwise specified, concrete and reinforced concrete shall conform to the requirements for 3000 psi concrete under Section 03 30 00 CAST-IN-PLACE CONCRETE. The concrete mixture shall have air content by volume of concrete, based on measurements made immediately after discharge from the mixer, of 5 to 7 percent when maximum size of coarse aggregate exceeds 1-1/2 inches. Air content shall be determined in accordance with ASTM C231/C231M. The concrete covering over steel reinforcing shall not be less than 2 inch thick for walls and flooring. Concrete covering deposited directly against the ground shall have a thickness of at least 3 inches between steel and ground. Expansion-joint filler material shall conform to ASTM D1751, or ASTM D1752, or shall be resin-impregnated fiberboard conforming to the physical requirements of ASTM D1752.

2.3.2 Mortar

Mortar for pipe joints, connections to other drainage structures, and brick or block construction shall conform to ASTM C270, Type M, except that the maximum placement time shall be 1 hour.

The quantity of water in the mixture shall be sufficient to produce a stiff workable mortar but in no case shall exceed [ ] liters gallons of water per sack of cement. Water shall be clean and free of harmful acids, alkalis, and organic impurities. The mortar shall be used within 30 minutes after the ingredients are mixed with water. The inside of the joint shall be wiped clean and finished smooth. The mortar head on the outside shall be protected from air and sun with a proper covering until satisfactorily cured.

2.3.3 Precast Concrete Segmental Blocks

Precast concrete segmental block shall conform to ASTM C139, not more than 8 inches thick, not less than 8 inches long, and of such shape that joints can be sealed effectively and bonded with cement mortar.

2.3.4 Joints

A. Flexible Watertight Joints

1. Flexible watertight joints shall be made with plastic or rubber-type gaskets for concrete pipe and with factory-fabricated resilient materials for clay pipe. The design of joints and the physical requirements for preformed flexible joint sealants shall conform to ASTM C990, and rubber-type gaskets shall conform to ASTM C443M ASTM C443.

Factory-fabricated resilient joint materials shall conform to ASTM C425. Gaskets shall have not more than one factory-fabricated splice, except that two factory-fabricated splices of the rubber-type gasket are permitted if the nominal diameter of the pipe being gasketed exceeds 54 inches.

2. Rubber gaskets shall comply with the oil resistant gasket requirements of ASTM C443M ASTM C443. Certified copies of test results shall be delivered to the Contracting Officer before gaskets or jointing materials are installed. Alternate types of watertight joint may be furnished, if specifically approved.

B. External Sealing Bands

Requirements for external sealing bands shall conform to ASTM C877M ASTM C877.

C.Flexible Watertight, Gasketed Joints

1. Gaskets: When infiltration or exfiltration is a concern for pipe lines, the couplings may be required to have gaskets. The closed-cell expanded rubber gaskets shall be a continuous band approximately 7 inches wide and approximately 3/8 inch thick, meeting the requirements of ASTM D1056, Type 2 [A1] [B3] and shall have a quality retention rating of not less than 70 percent when tested for weather resistance by ozone chamber exposure, Method B of ASTM D1171. Rubber O-ring gaskets shall be 13/16 inch in diameter for pipe diameters of 914 mm 36 inches or smaller and 7/8 inch in diameter for larger pipe having 13 mm 1/2 inch deep end corrugation. Rubber O-ring gaskets shall be 1-3/8 inches in diameter for pipe having 1 inch deep end corrugations. O-rings shall meet the requirements of ASTM C990 or ASTM C443M ASTM C443. Preformed flexible joint sealants shall conform to ASTM C990, Type B.

2. Connecting Bands: Connecting bands shall be of the type, size and sheet thickness of band, and the size of angles, bolts, rods and lugs as indicated or where not indicated as specified in the applicable standards or specifications for the pipe. Exterior rivet heads in the longitudinal seam under the connecting band shall be countersunk or the rivets shall be omitted and the seam welded.

2.4 EROSION CONTROL RIP RAP

Provide non-erodible rock not exceeding 15 inches in its greatest dimension and choked with sufficient small rocks to provide a dense mass with a minimum thickness of 12 inches

PART 3 EXECUTION

3.1 INSTALLATION OF PIPE CULVERTS AND DRAINAGE STRUCTURES

Excavation of trenches, and for appurtenances and backfilling for culverts and drainage structures shall be in accordance with industry standards for earthwork and the requirements specified below.

3.1.1 Trenching

The width of trenches at any point below the top of the pipe shall be not greater than the outside diameter of the pipe plus 12 inches to permit satisfactory jointing and thorough tamping of the bedding material under and around the pipe. Sheeting and bracing, where required, shall be placed within the trench width as specified, without any over excavation.

Where trench widths are exceeded, redesign with a resultant increase in cost of stronger pipe or special installation procedures will be necessary. Cost of this redesign and increased cost of pipe or installation shall be borne by the contractor without additional cost to the Government.

3.1.2 Removal of Rock

Rock in either ledge or boulder formation shall be replaced with suitable materials to provide a compacted earth cushion having a thickness between unremoved rock and the pipe of at least 8 inches or 1/2 inch for each meter foot of fill over the top of the pipe, whichever is greater, but not more than three-fourths the nominal diameter of the pipe. Where bell-and-spigot pipe is used, the cushion shall be maintained under the bell as well as under the straight portion of the pipe.

3.1.3 Removal of Unstable Material

Where wet or otherwise unstable soil incapable of properly supporting the pipe, as determined by the Contracting Officer, is unexpectedly encountered in the bottom of a trench, such material shall be removed to the depth required and replaced to the proper grade with select granular material, compacted as provided in paragraph BACKFILLING.

When removal of unstable material is due to the fault or neglect of the Contractor while performing shoring and sheeting, water removal, or other specified requirements, such removal and replacement shall be performed at no additional cost to the Government.

3.2 BEDDING

The bedding surface for the pipe shall provide a firm foundation of uniform density throughout the entire length of the pipe.

3.2.1 Concrete Pipe Requirements

When no bedding class is specified or detailed on the drawings, concrete pipe shall be bedded in granular material minimum 4 inch in depth in trenches with soil foundation. Depth of granular bedding in trenches with rock foundation shall be 1/2 inch in depth per foot of depth of fill, minimum depth of bedding shall be 8 inch up to maximum depth of 24 inches.

The middle third of the granular bedding shall be loosely placed. Bell holes and depressions for joints shall be removed and formed so entire barrel of pipe is uniformly supported. The bell hole and depressions for the joints shall be not more than the length, depth, and width required for properly making the particular type of joint.

3.3 PLACING PIPE

Each pipe shall be thoroughly examined before being laid; defective or damaged pipe shall not be used. Plastic pipe, excluding SRPE pipe shall be protected from exposure to direct sunlight prior to laying, if necessary to maintain adequate pipe stiffness and meet installation deflection requirements. Pipelines shall be laid to the grades and alignment indicated. Proper facilities shall be provided for lowering sections of pipe into trenches. Lifting lugs in vertically elongated pipe shall be placed in the same vertical plane as the major axis of the pipe. Pipe shall not be laid in water, and pipe shall not be laid when trench conditions or weather are unsuitable for such work. Diversion of drainage or dewatering of trenches during construction shall be provided as necessary. Deflection of installed flexible pipe shall not exceed the following limits:

3.3.1 Concrete

Laying shall proceed upgrade with spigot ends of bell-and-spigot pipe and tongue ends of tongue-and-groove pipe pointing in the direction of the flow.

3.3.2 Multiple Culverts

Where multiple lines of pipe are installed, adjacent sides of pipe shall be at least half the nominal pipe diameter or 1 meter 3 feet apart, whichever is less.

3.3.3 Jacking Pipe Through Fills

Methods of operation and installation for jacking pipe through fills shall conform to requirements specified in Volume 1, Chapter 1, Part 4 of AREMA Eng Man.

3.4 JOINTING

3.4.1 Concrete Pipe

A. Cement-Mortar Bell-and-Spigot Joint

The first pipe shall be bedded to the established grade line, with the bell end placed upstream. The interior surface of the bell shall be thoroughly cleaned with a wet brush and the lower portion of the bell filled with mortar as required to bring inner surfaces of abutting pipes flush and even. The spigot end of each subsequent pipe shall be cleaned with a wet brush and uniformly matched into a bell so that sections are closely fitted. After each section is laid, the remainder of the joint shall be filled with mortar, and a bead shall be formed around the outside of the joint with sufficient additional mortar. If mortar is not sufficiently stiff to prevent appreciable slump before setting, the outside of the joint shall be wrapped or bandaged with cheesecloth to hold mortar in place.

B. Cement-Mortar Oakum Joint for Bell-and-Spigot Pipe

A closely twisted gasket shall be made of jute or oakum of the diameter required to support the spigot end of the pipe at the proper grade and to make the joint concentric. Joint packing shall be in one piece of sufficient length to pass around the pipe and lap at top. This gasket shall be thoroughly saturated with neat cement grout. The bell of the pipe shall be thoroughly cleaned with a wet brush, and the gasket shall be laid in the bell for the lower third of the circumference and covered with mortar. The spigot of the pipe shall be thoroughly cleaned with a wet brush, inserted in the bell, and carefully driven home. A small amount of mortar shall be inserted in the annular space for the upper two-thirds of the circumference. The gasket shall be lapped at the top of the pipe and driven home in the annular space with a caulking tool. The remainder of the annular space shall be filled completely with mortar and beveled at an angle of approximately 45 degrees with the outside of the bell. If mortar is not sufficiently stiff to prevent appreciable slump before setting, the outside of the joint thus made shall be wrapped with cheesecloth. Placing of this type of joint shall be kept at least five joints behind laying operations.

1. Cement-Mortar Diaper Joint for Bell-and-Spigot Pipe

The pipe shall be centered so that the annular space is uniform. The annular space shall be caulked with jute or oakum. Before caulking, the inside of the bell and the outside of the spigot shall be cleaned.

a. Diaper Bands: Diaper bands shall consist of heavy cloth fabric to hold grout in place at joints and shall be cut in lengths that extend one-eighth of the circumference of pipe above the spring line on one side of the pipe and up to the spring line on the other side of the pipe. Longitudinal edges of fabric bands shall be rolled and stitched around two pieces of wire. Width of fabric bands shall be such that after fabric has been securely stitched around both edges on wires, the wires will be uniformly spaced not less than 8 inches apart. Wires shall be cut into lengths to pass around pipe with sufficient extra length for the ends to be twisted at top of pipe to hold the band securely in place; bands shall be accurately centered around lower portion of joint.

b. Grout: Grout shall be poured between band and pipe from the high side of band only, until grout rises to the top of band at the spring line of pipe, or as nearly so as possible, on the opposite side of pipe, to ensure a thorough sealing of joint around the portion of pipe covered by the band. Silt, slush, water, or polluted mortar grout forced up on the lower side shall be forced out by pouring, and removed.

c. Remainder of Joint: The remaining unfilled upper portion of the joint shall be filled with mortar and a bead formed around the outside of this upper portion of the joint with a sufficient amount of additional mortar. The diaper shall be left in place. Placing of this type of joint shall be kept at least five joints behind actual laying of pipe. No backfilling around joints shall be done until joints have been fully inspected and approved.

2. Cement-Mortar Tongue-and-Groove Joint

The first pipe shall be bedded carefully to the established grade line with the groove upstream. A shallow excavation shall be made underneath the pipe at the joint and filled with mortar to provide a bed for the pipe. The grooved end of the first pipe shall be thoroughly cleaned with a wet brush, and a layer of soft mortar applied to the lower half of the groove. The tongue of the second pipe shall be cleaned with a wet brush; while in horizontal position, a layer of soft mortar shall be applied to the upper half of the tongue.

The tongue end of the second pipe shall be inserted in the grooved end of the first pipe until mortar is squeezed out on interior and exterior surfaces. Sufficient mortar shall be used to fill the joint completely and to form a bead on the outside.

3. Cement-Mortar Diaper Joint for Tongue-and-Groove Pipe The joint shall be of the type described for cement-mortar tongue-and-groove joint in this paragraph, except that the shallow excavation directly beneath the joint shall not be filled with mortar until after a gauze or cheesecloth band dipped in cement mortar has been wrapped around the outside of the joint. The cement-mortar bead at the joint shall be at least 1/2 inch, thick and the width of the diaper band shall be at least 8 inches. The diaper shall be left in place. Placing of this type of joint shall be kept at least five joints behind the actual laying of the pipe. Backfilling around the joints shall not be done until the joints have been fully inspected and approved.

4. Plastic Sealing Compound Joints for Tongue-and-Grooved Pipe: Sealing compounds shall follow the recommendation of the particular manufacturer in regard to special installation requirements. Surfaces to receive lubricants, primers, or adhesives shall be dry and clean. Sealing compounds shall be affixed to the pipe not more than 3 hours prior to installation of the pipe, and shall be protected from the sun, blowing dust, and other deleterious agents at all times. Sealing compounds shall be inspected before installation of the pipe, and any loose or improperly affixed sealing compound shall be removed and replaced. The pipe shall be aligned with the previously installed pipe, and the joint pulled together. If, while making the joint with mastic-type sealant, a slight protrusion of the material is not visible along the entire inner and outer circumference of the joint when the joint is pulled up, the pipe shall be removed and the joint remade.

After the joint is made, all inner protrusions shall be cut off flush with the inner surface of the pipe. If non-mastic-type sealant material is used, the "Squeeze-Out" requirement above will be waived.

5. Flexible Watertight Joints: Gaskets and jointing materials shall be as recommended by the particular manufacturer in regard to use of lubricants, cements, adhesives, and other special installation requirements. Surfaces to receive lubricants, cements, or adhesives shall be clean and dry. Gaskets and jointing materials shall be affixed to the pipe not more than 24 hours prior to the installation of the pipe, and shall be protected from the sun, blowing dust, and other deleterious agents at all times. Gaskets and jointing materials shall be inspected before installing the pipe; any loose or improperly affixed gaskets and jointing materials shall be removed and replaced. The pipe shall be aligned with the previously installed pipe, and the joint pushed home. If, while the joint is being made the gasket becomes visibly dislocated the pipe shall be removed and the joint remade.

6. External Sealing Band Joint for Noncircular Pipe: Surfaces to receive sealing bands shall be dry and clean. Bands shall be installed in accordance with manufacturer's recommendations.

3.5 DRAINAGE STRUCTURES

3.5.1 Walls and Headwalls

Construction shall be as indicated.

3.6 BACKFILLING

3.6.1 Backfilling Pipe in Trenches

After the pipe has been properly bedded, selected material from excavation or borrow, at a moisture content that will facilitate compaction, shall be placed along both sides of pipe in layers not exceeding 6 inches in compacted depth. The backfill shall be brought up evenly on both sides of pipe for the full length of pipe. The fill shall be thoroughly compacted under the haunches of the pipe. Each layer shall be thoroughly compacted with mechanical tampers or rammers. This method of filling and compacting shall continue until the fill has reached an elevation equal to the midpoint (spring line) of concrete pipe or has reached an elevation of at least 12 inches above the top of the pipe for flexible pipe. The remainder of the trench shall be backfilled and compacted by spreading and rolling or compacted by mechanical rammers or tampers in layers not exceeding8 inches. Tests for density shall be made as necessary to ensure conformance to the compaction requirements specified below. Where it is necessary, in the opinion of the COR, that sheeting or portions of bracing used be left in place, the contract will be adjusted accordingly. Untreated sheeting shall not be left in place beneath structures or pavements.

3.6.2 Backfilling Pipe in Fill Sections

For pipe placed in fill sections, backfill material and the placement and compaction procedures shall be as specified below. The fill material shall be uniformly spread in layers longitudinally on both sides of the pipe, not exceeding 6 inches in compacted depth, and shall be compacted by rolling parallel with pipe or by mechanical tamping or ramming. Prior to commencing normal filling operations, the crown width of the fill at a height of 12 inches above the top of the pipe shall extend a distance of not less than twice the outside pipe diameter on each side of the pipe or 12 feet, whichever is less. After the backfill has reached at least 12 inches above the top of the pipe, the remainder of the fill shall be placed and thoroughly compacted in layers not exceeding 8 inches. Use select granular material for this entire region of backfill for flexible pipe installations.

3.6.3 Movement of Construction Machinery

When compacting by rolling or operating heavy equipment parallel with the pipe, displacement of or injury to the pipe shall be avoided. Movement of construction machinery over a culvert or storm drain at any stage of construction shall be at the contractor's risk. Any damaged pipe shall be repaired or replaced.

3.6.4 Compaction

A. General Requirements

Cohesionless materials include gravels, gravel-sand mixtures, sands, and gravelly sands.

Cohesive materials include clayey and silty gravels, gravel-silt mixtures, clayey and silty sands, sand-clay mixtures, clays, silts, and very fine sands. When results of compaction tests for moisture-density relations are recorded on graphs, cohesionless soils will show straight lines or reverse-shaped moisture-density curves, and cohesive soils will show normal moisture-density curves.

B. Minimum Density

Backfill over and around the pipe and backfill around and adjacent to drainage structures shall be compacted at the approved moisture content to the following applicable minimum density, which will be determined as specified below.

1. Under airfield and heliport pavements, paved roads, streets, parking areas, and similar-use pavements including adjacent shoulder areas, the density shall be not less than 90 percent of maximum density for cohesive material and 95 percent of maximum density for cohesionless material, up to the elevation where requirements for pavement subgrade materials and compaction shall control.

2. Under unpaved or turfed traffic areas, density shall not be less than 90 percent of maximum density for cohesive material and 95 percent of maximum density for cohesionless material.

3. Under nontraffic areas, density shall be not less than that of the surrounding material.

3.7 FIELD PAINTING

3.7.1 Concrete Frames

After installation, clean steel or concrete, not buried in masonry or concrete, of mortar, dirt, grease, and other deleterious materials to bare metal. Apply a coat of primer, to a minimum dry film thickness of [] mil; and apply a top coat, to a minimum dry film thickness of mils, color optional. Do not paint surfaces subject to abrasion.

3.8 FIELD QUALITY CONTROL

3.8.1 Tests

Testing is the responsibility of the contractor. Perform all testing and retesting at no additional cost to the Government.

A. HYDROSTATIC TEST ON WATERTIGHT JOINTS

Watertight joints shall be tested and shall meet test requirements of paragraph HYDROSTATIC TEST ON WATERTIGHT JOINTS. Rubber gaskets shall comply with the oil resistant gasket requirements of ASTM C443M ASTM C443. Certified copies of test results shall be delivered to the Contracting Officer before gaskets or jointing materials are installed.

2. Concrete

A hydrostatic test shall be made on the watertight joint types as proposed. Only one sample joint of each type needs testing; however, if the sample joint fails because of faulty design or workmanship, an additional sample joint may be tested. During the test period, gaskets or other jointing material shall be protected from extreme temperatures which might adversely affect the performance of such materials. Performance requirements for joints in reinforced and nonreinforced concrete pipe shall conform to ASTM C990 or ASTM C443M ASTM C443. Test requirements for joints in clay pipe shall conform to ASTM C425. Test requirements for joints in PVC, PE, and PP plastic pipe shall conform to ASTM D3212.

B. Leakage Test

Lines shall be tested for leakage by low pressure air or water testing or exfiltration tests, as appropriate, prior to completing backfill. Low pressure air testing for vitrified clay pipes shall conform to ASTM C828. Low pressure air testing for concrete pipes shall conform to ASTM C969M ASTM C969. Low pressure air testing for plastic pipe shall conform to ASTM F1417.

Low pressure air testing procedures for other pipe materials shall use the pressures and testing times prescribed in ASTM C828 or ASTM C969M ASTM C969, after consultation with the pipe manufacturer. Testing of individual joints for leakage by low pressure air or water shall conform to ASTM C1103M ASTM C1103. Prior to exfiltration tests, the trench shall be backfilled up to at least the lower half of the pipe. If required, sufficient additional backfill shall be placed to prevent pipe movement during testing, leaving the joints uncovered to permit inspection. Visible leaks encountered shall be corrected regardless of leakage test results.

When the water table is 2 feet or more above the top of the pipe at the upper end of the pipeline section to be tested, infiltration shall be measured using a suitable weir or other device acceptable to the COR. An exfiltration test shall be made by filling the line to be tested with water so that a head of at least 2 feet is provided above both the water table and the top of the pipe at the upper end of the pipeline to be tested. The filled line shall be allowed to stand until the pipe has reached its maximum absorption, but not less than 4 hours. After absorption, the head shall be reestablished. The amount of water required to maintain this water level during a 2-hour test period shall be measured. Leakage as measured by the exfiltration test shall not exceed [60 liters per in diameter per kilometer 250 gallons per inch in diameter per mile of pipeline per day] [9 mL per mm in diameter per 100 meters 0.2 gallons per inch in diameter per 100 feet of pipeline per hour].

C. Determination of Density

Testing shall be performed by an approved commercial testing laboratory or by the contractor subject to approval. Tests shall be performed in sufficient number to ensure that specified density is being obtained. Laboratory tests for moisture-density relations shall be made in accordance with ASTM D1557 except that mechanical tampers may be used provided the results are correlated with those obtained with the specified hand tamper. Field density tests shall be determined in accordance with ASTM D2167 or ASTM D6938. When ASTM D6938 is used, the calibration curves shall be checked and adjusted, if necessary, using the sand cone method as described in paragraph Calibration of the referenced publications. ASTM D6938 results in a wet unit weight of soil and ASTM D6938 shall be used to determine the moisture content of the soil. The calibration curves furnished with the moisture gauges shall be checked along with density calibration checks as described in ASTM D6938. Test results shall be furnished the COR. The calibration checks of both the density and moisture gauges shall be made at the beginning of a job on each different type of material encountered and at intervals as directed.

D. Deflection Testing

Conduct deflection test no sooner than 30 days after completion of final backfill and compaction testing. Clean or flush all lines prior to testing. Perform a deflection test on entire length of installed flexible pipeline upon completion of work adjacent to and over the pipeline, including backfilling, placement of fill, grading, paving, placement of concrete, and any other superimposed loads. Deflection of pipe in the installed pipeline under external loads shall not exceed limits in paragraph PLACING PIPE above as percent of the average inside diameter of pipe. Use a laser profiler or mandrel to determine if allowable deflection has been exceeded.

1. Laser Profiler

Inspect pipe interior with laser profiling equipment. Utilize low barrel distortion video equipment for pipe sizes 48 inches or less. Use a camera with suitable lighting to allow a clear picture of the entire periphery of the pipe interior. Center the camera in the pipe both vertically and horizontally. The camera must be able to pan and tilt to a 90 degree angle with the axis of the pipe rotating 360 degrees. Use equipment to move the camera through the pipe that will not obstruct the camera's view or interfere with proper documentation of the pipe's condition. The video image shall be clear, focused, and relatively free from roll static or other image distortion qualities that would prevent the reviewer from evaluating the condition of the pipe. For initial post installation inspections for pipe sizes larger than 48 inches, a visual inspection shall be completed of the pipe interior.

2. Mandrel

Pass the mandrel through each run of pipe by pulling it by hand. If deflection readings in excess of the allowable deflection of average inside diameter of pipe are obtained, stop and begin test from the opposite direction. The mandrel must meet the Pipe Manufacture's recommendations and the following requirements. Provide a Mandrel that is rigid, nonadjustable, has a minimum of 9 fins, pulling rings at each end, and is engraved with the nominal pipe size and mandrel outside diameter. The mandrel must be 5 percent less than the certified-actual pipe diameter for Plastic Pipe, 5 percent less than the certified-actual pipe diameter for Corrugated Steel and Aluminum, 3 percent less than the certified-actual pipe diameter for Concrete-Lined Corrugated Steel and Ductile Iron Culvert. The Government will verify the outside diameter (OD)of the Contractor provided mandrel through the use of Contractor provided proving rings.

3.8.2 Inspection

A. Post-Installation Inspection

Visually inspect each segment of concrete pipe for alignment, settlement, joint separations, soil migration through the joint, cracks, buckling, bulging and deflection. An engineer must evaluate all defects to determine if any remediation or repair is required.

3.8.2.1.1 Concrete

Cracks with a width greater than 0.01 inches. An engineer must evaluate all pipes with cracks with a width greater than 0.01 inches but less than 0.10 inches to determine if any remediation or repair is required.

3.8.2.1.2 Post-Installation Inspection Report

The deflection results and final post installation inspection report must include: [a copy of all video taken, ]pipe location identification, equipment used for inspection, inspector name, deviation from design, grade, deviation from line, deflection and deformation of flexible pipe, inspector notes, condition of joints, condition of pipe wall (e.g. distress, cracking, wall damage dents, bulges, creases, tears, holes, etc.).

When as-built drawings show deviations to the LID features, document the deviations on the LID Verification Report.

3.8.3 Repair Of Defects

A. Leakage Test

When leakage exceeds the maximum amount specified, correct source of excess leakage by replacing damaged pipe and gaskets and retest.

B. Deflection Testing

When deflection readings are in excess of the allowable deflection of average inside diameter of pipe are obtained, remove pipe which has excessive deflection and replace with new pipe.

Retest 30 days after completing backfill, leakage testing and compaction testing.

C. Inspection

Replace c or repair defects indicated in the Post-Installation Inspection Report.

Concrete: Replace culverts having cracks with a width greater than 0.1 inches.

3.9 PROTECTION

Protect storm drainage piping and adjacent areas from superimposed and external loads during construction.

3.10 WARRANTY PERIOD

Pipe segments found to have defects during the warranty period must be replaced with new pipe and retested.

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