33_40_00_Amendment_0003.pdf

FY16 UNDERWOOD CREEK ECOSYSTEM RESTORATION FY16UNDERWOODCR

Amendment 0003

SECTION TABLE OF CONTENTS

DIVISION 33 - UTILITIES

SECTION 33 40 00

STORM DRAINAGE UTILITIES

PART 1 GENERAL

1.1 SECTION SCOPE

1.2 REFERENCES

1.3 SUBMITTALS

1.4 104th Steet and Golf Cart Path Outfall Design

1.4.1 Design Team

1.4.2 Design Standards

1.4.3 Design Submittals

1.4.4 104th Street Outfall Site Specific Design Requirements

1.4.5 Golf Cart Path Outfall Site Specific Design Requirements

1.5 DELIVERY, STORAGE, AND HANDLING

1.5.1 Delivery and Storage

1.5.2 Handling

PART 2 PRODUCTS

2.1 PIPE FOR CULVERTS AND STORM DRAINS

2.1.1 Concrete Pipe

2.1.1.1 Reinforced Elliptical Culvert and Storm Drainpipe

2.2 DRAINAGE STRUCTURES

2.2.1 Flared End Sections

2.2.2 Precast Reinforced Concrete Box

2.3 MISCELLANEOUS MATERIALS

2.3.1 Concrete

2.3.2 Mortar

2.3.3 Joints

2.3.3.1 Flexible Watertight Joints

2.3.3.2 External Sealing Bands

2.3.3.3 Flexible Watertight, Gasketed Joints

2.4 RESILIENT CONNECTORS

2.5 EROSION CONTROL RIPRAP

PART 3 EXECUTION

3.1 EXCAVATION FOR PIPE CULVERTS, STORM DRAINS, AND DRAINAGE STRUCTURES

3.1.1 Trenching

3.1.2 Removal of Rock

3.1.3 Removal of Unstable Material

3.2 BEDDING

3.2.1 Concrete Pipe Requirements

3.3 PLACING PIPE

3.3.1 Concrete Pipe

3.3.2 Elliptical and Elliptical Reinforced Concrete Pipe

3.3.3 Multiple Culverts

3.4 JOINTING

SECTION 33 40 00 Page 1

3.4.1 Concrete and Clay Pipe

3.4.1.1 Cement-Mortar Bell-and-Spigot Joint

3.4.1.2 Cement-Mortar Oakum Joint for Bell-and-Spigot Pipe

3.4.1.3 Cement-Mortar Diaper Joint for Bell-and-Spigot Pipe

3.4.1.4 Cement-Mortar Tongue-and-Groove Joint

3.4.1.5 Cement-Mortar Diaper Joint for Tongue-and-Groove Pipe

3.4.1.6 Plastic Sealing Compound Joints for Tongue-and-Grooved Pipe

3.4.1.7 Flexible Watertight Joints

3.4.1.8 External Sealing Band Joint for Noncircular Pipe

3.5 DRAINAGE STRUCTURES

3.5.1 Manholes and Inlets

3.5.2 Apron Endwalls

3.5.2.1 Steel Apron Endwalls

3.5.2.2 Concrete Apron Endwalls

3.6 BACKFILLING

3.6.1 Backfilling Pipe in Trenches

3.6.2 Backfilling Pipe in Fill Sections

3.6.3 Movement of Construction Machinery

3.6.4 Compaction

3.6.4.1 General Requirements

3.6.4.2 Minimum Density

3.6.5 Determination of Density

3.7 PIPELINE TESTING

3.7.1 Leakage Tests

3.7.2 Deflection Testing

3.7.3 Post-Installation Inspection

-- End of Section Table of Contents --

SECTION 33 40 00 Page 2

SECTION 33 40 00

STORM DRAINAGE UTILITIES

PART 1 GENERAL

1.1 SECTION SCOPE

This specification section applies to the design and construction of the 104th Street Outfall and the construction of other outfalls (except 103rd Street) as shown on the project drawings or as encountered during construction operations. See additional specifications for the requirements associated with the 103rd Street Outfall.

1.2 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.

ASTM INTERNATIONAL (ASTM)

ASTM C1103 (2014) Standard Practice for Joint Acceptance Testing of Installed Precast Concrete Pipe Sewer Lines

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

ASTM C231/C231M (2014) 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 C425 (2004; R 2013) Standard Specification for Compression Joints for Vitrified Clay Pipe and Fittings

ASTM C443 (2011) Standard Specification for Joints for Concrete Pipe and Manholes, Using Rubber Gaskets

ASTM C507 (2015) Standard Specification for Reinforced Concrete Elliptical Culvert, Storm Drain, and Sewer Pipe

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

ASTM C877 (2008) External Sealing Bands for Concrete

SECTION 33 40 00 Page 3

Pipe, Manholes, and Precast Box Sections

ASTM C923 (2008; R 2013; E 2016) Standard Specification for Resilient Connectors Between Reinforced Concrete Manhole Structures, Pipes and Laterals

ASTM C969 (2002; R 2009) Standard Practice for Infiltration and Exfiltration Acceptance Testing of Installed Precast Concrete Pipe Sewer Lines

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) Rubber Deterioration - Surface Ozone Cracking Outdoors or Chamber (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 D1752 (2004a; R 2013) Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion

ASTM D2167 (2015) Density and Unit Weight of Soil in Place by the Rubber Balloon Method

ASTM D6938 (2015) Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth)

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Outfall Design Team Directory; G, ECG

SECTION 33 40 00 Page 4

SD-03 Product Data

Placing Pipe

Submit printed copies of the manufacturer's recommendations for installation procedures of the material being placed, prior to installation. This shall include detailed layout shop drawings.

SD-04 Samples

Pipe for Culverts and Storm Drains

SD-07 Certificates

Resin Certification

Pipeline Testing

Hydrostatic Test on Watertight Joints

Determination of Density

Frame and Cover for Gratings

1.4 104th Steet and Golf Cart Path Outfall Design

The contractor is required to develop the complete design of the 104th Street and Golf Cart Path Outfall structures as indicated on the project drawings and in this specification. The material and installation requirements of this specification shall be met in the contractor's design and installation of the outfall structure. "Outfall Structure" is defined as any pipe, manhole, joints, bedding, excavation, grading, headwalls, and other outlet components necessary to provide a connection from the existing storm sewer utility at 104th Street to Underwood Creek and provide drainage of the golf cart pathway and drainage area behind the wall structures. The design of the components shall meet the following requiements:

1.4.1 Design Team

The contractor shall assemble a design team to complete the design of the outfall structure. The team shall include, as necessary, the following team members: Civil Engineer, Structural Engineer, Geotechnical Engineer, Hydraulic Engineer. Within 15 days after contract award the contractor shall submit an Outfall Design Team Directory which includes the names and role of each team member. It shall also include resumes for each team member documenting the experience of each team member on similar projects.

All team members shall have at least 5 years of experience in storm sewer design and be registered as Professional Engineers in the State of Wisconsin.

1.4.2 Design Standards

The outfall structures design shall meet all applicable requirements set by the Wisconsin Department of Transportation, ASTM, ACI, USACE and AWWA. Any variance from these standards shall be documented in the design documentation report and approved by the COR.

SECTION 33 40 00 Page 5

1.4.3 Design Submittals

The contractor shall prepare the following intermediate design submittals for review by the COR before the outfall will be released for construction:

50% Outfall Structures Review Submittal, 95% Outfall Structures Review Submittal, and Ready for Construction Outfall Structures Review Submittal.

Submittal requirments are found in Section 01 33 16 Design After Award.

1.4.4 104th Street Outfall Site Specific Design Requirements

As shown on the project plans in the location of the outfall is an SSP retaining wall. Design of the outfall structure shall include all necessary pentrations or top elevation adjustments through the SSP wall. Any adjustment to the top elevation of the SSP shall be reviewed and approved by the COR prior to any design work on that component proceeding. The alignment of the SSP wall shall not be changed and it shall be remain continuous (at the specified tip elevation). No complete break in the SSP wall is permitted. The culvert shall extend to the SSP wall. All outfall strucutre components shall be made of reinforced concrete (Pre Cast or Cast in Place). The outlet pipe culvert size shall match the existing sanitary sewer pipe. No restrictions to flow are permitted. The culvert shall be an open structure. No fully enclosed culvert pipe will be permitted within the project limits. It is required to extend the 7'x8' box culvert to the SSP and design and build an endwall section at the proposed SSP. The existing HDPE shall be removed.

1.4.5 Golf Cart Path Outfall Site Specific Design Requirements

Design of the outfall or other type of drainage structure shall include all necessary pentrations or top elevation adjustments through the SSP wall.

Any adjustment to the top elevation of the SSP shall be reviewed and approved by the COR prior to any design work on that component proceeding.

The alignment of the SSP wall shall not be changed and it shall be remain continuous (at the specified tip elevation). No complete break in the SSP wall is permitted. The design shall consider passing the flows resulting from the entire drainage area as determined by the design engineer. The designer shall consider the utilization of catch basins, man holes, and trench drains in the design.

1.5 DELIVERY, STORAGE, AND HANDLING

1.5.1 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 Contracting Officer.

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.

SECTION 33 40 00 Page 6

1.5.2 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 PIPE FOR CULVERTS AND STORM DRAINS

Pipe for culverts and storm drains shall be of the sizes indicated and shall conform to the requirements specified.

2.1.1 Concrete Pipe

Manufactured in accordance with and conforming to ASTM C76. RCP shall be Class III (18" and larger), Class IV for 15", and Class V for 12", unless noted otherwise.

2.1.1.1 Reinforced Elliptical Culvert and Storm Drainpipe

Manufactured in accordance with and conforming to ASTM C507.

2.2 DRAINAGE STRUCTURES

2.2.1 Flared End Sections

Sections shall be of a standard design fabricated with cast in place or pre cast concrete.

2.2.2 Precast Reinforced Concrete Box

Manufactured in accordance with and conforming to ASTM C1433.

2.3 MISCELLANEOUS MATERIALS

2.3.1 Concrete

Unless otherwise specified, concrete and reinforced concrete shall conform to the requirements for 4000 psi concrete under Section 03 31 01.00 10 CAST IN PLACE STRUCTURAL CONCRETE FOR CIVIL WORKS. 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 1 inch thick for covers and not less than 1-1/2 inches 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 the maximum amount of water per sack of cement permitted

SECTION 33 40 00 Page 7 by the manufacturer. 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 Joints

2.3.3.1 Flexible Watertight Joints

a. Materials: 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 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.

b. Test Requirements: 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 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.

2.3.3.2 External Sealing Bands

Requirements for external sealing bands shall conform to ASTM C877.

2.3.3.3 Flexible Watertight, Gasketed Joints

a. 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, 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 36 inches or smaller and 7/8 inch in diameter for larger pipe having 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 C443. Preformed flexible joint sealants shall conform to ASTM C990, Type B.

b. 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. Watertight joints shall be tested and shall meet the test requirements of paragraph HYDROSTATIC

TEST ON WATERTIGHT JOINTS.

SECTION 33 40 00 Page 8

2.4 RESILIENT CONNECTORS

Flexible, watertight connectors used for connecting pipe to manholes and inlets shall conform to ASTM C923.

2.5 EROSION CONTROL RIPRAP

Provide nonerodible rock choked with sufficient small rocks to provide a dense mass with a minimum thickness as indicated.

PART 3 EXECUTION

3.1 EXCAVATION FOR PIPE CULVERTS, STORM DRAINS, AND DRAINAGE STRUCTURES

Excavation of trenches, and for appurtenances and backfilling for culverts and storm drains, shall be in accordance with the applicable portions of Section 31 00 00 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 wide enough 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 overexcavation. 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 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. Rock excavation shall be as specified and defined in Section 31 00 00 EARTHWORK.

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.

SECTION 33 40 00 Page 9

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. 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 metal 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.

Note post installation requirements of paragraph DEFLECTION TESTING in PART 3 of this specification for all pipe products.

3.3.1 Concrete Pipe

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 Elliptical and Elliptical Reinforced Concrete Pipe

The manufacturer's reference lines, designating the top of the pipe, shall be within 5 degrees of a vertical plane through the longitudinal axis of the pipe, during placement. Damage to or misalignment of the pipe shall be prevented in all backfilling operations.

3.3.3 Multiple Culverts

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

3.4 JOINTING

3.4.1 Concrete and Clay Pipe

3.4.1.1 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

SECTION 33 40 00 Page 10 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.

3.4.1.2 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.

3.4.1.3 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.

SECTION 33 40 00 Page 11

3.4.1.4 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.

3.4.1.5 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.

3.4.1.6 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.

3.4.1.7 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.

SECTION 33 40 00 Page 12

3.4.1.8 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 Manholes and Inlets

Construction shall be of reinforced concrete, plain concrete, brick, precast reinforced concrete, precast concrete segmental blocks, prefabricated corrugated metal, or bituminous coated corrugated metal;

complete with frames and covers or gratings; and with fixed galvanized steel ladders where indicated. Pipe studs and junction chambers of prefabricated corrugated metal manholes shall be fully bituminous-coated and paved when the connecting branch lines are so treated. Pipe connections to concrete manholes and inlets shall be made with flexible, watertight connectors.

3.5.2 Apron Endwalls

3.5.2.1 Steel Apron Endwalls

Steel apron endwalls, complying with Sections 520 and 521 of the Wisconsin Department of Transportation Standard Specifications and the Standard Detail Drawings 8 F 1 through 11 shall be installed at the ends of all corrugated steel culvert pipe.

Corrugated steel culvert pipe (if needed) shall be furnished for the following minimum gages/thicknesses.

6 (or equivalent diameter) CSCP 18 gage (0.052 in.)

8 thru 24 (or equivalent diameter) CSCP 16 gage (0.064 in.)

30 & 36 (or equivalent diameter) CSCP 14 gage (0.079 in.)

Pipe and endwalls shall have a protective coating as specified in AASHTO M36.

3.5.2.2 Concrete Apron Endwalls

Concrete apron endwalls shall be in accordance with WisDOT Standard Detail Drawings 8 F 1 through 11 and shall be tied to the concrete storm sewer pipe in the manner illustrated on the WisDOT Standard Detail Drawing 8 F 4-7.

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

SECTION 33 40 00 Page 13 shall continue until the fill has reached an elevation equal to the midpoint (spring line) of RCP 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 exceeding 9 inches (loose thickness). 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 Contracting Officer, 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 9 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

3.6.4.1 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.

3.6.4.2 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.

a. 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

SECTION 33 40 00 Page 14 material, up to the elevation where requirements for pavement subgrade materials and compaction shall control.

b. 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.

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

3.6.5 Determination of Density

Testing is the responsibility of the Contractor and performed at no additional cost to the Government. 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 Contracting Officer. 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.

3.7 PIPELINE TESTING

3.7.1 Leakage Tests

Lines shall be tested for leakage by low pressure air or water testing or exfiltration tests, as appropriate. Low pressure air testing for concrete pipes shall conform to ASTM C969. Testing of individual joints for leakage by low pressure air or water shall conform to 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 Contracting Officer. 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 0.2 gallons per inch in diameter per 100 feet of pipeline per hour. When leakage exceeds the maximum amount specified, satisfactory correction shall be made and retesting accomplished.

SECTION 33 40 00 Page 15

3.7.2 Deflection Testing

No sooner than 30 days after completion of installation and final backfill, an initial post installation inspection shall be accomplished. Clean or flush all lines prior to inspection. Perform a deflection test on entire length of installed flexible pipeline on completion of work adjacent to and over the pipeline, including leakage tests, backfilling, placement of fill, grading, paving, concreting, 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. Determine whether the allowable deflection has been exceeded by use of a laser profiler or mandrel.

a. Laser Profiler Inspection: If deflection readings 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.

Initial post installation inspections of the pipe interior with laser profiling equipment shall utilize low barrel distortion video equipment for pipe sizes 48 inches or less. Use a camera with lighting suitable to allow a clear picture of the entire periphery of the pipe interior.

Center the camera in the pipe both vertically and horizontally and 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, visual inspection shall be completed of the pipe interior.

b. Pull-Through Device Inspection: Pass the pull-through device 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, retest pipe by a run from the opposite direction. If retest continues to show excess allowable deflections of the average inside diameter of pipe, remove pipe which has excessive deflection, replace with new pipe, and completely retest in same manner and under same conditions. Pull-through device: The mandrel shall be rigid, nonadjustable having a minimum of 9 fins, including pulling rings at each end, engraved with the nominal pipe size and mandrel outside diameter. The mandrel shall 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 Alloy, 3 percent less than the certified-actual pipe diameter for Concrete-Lined Corrugated Steel and Ductile Iron Culvert provided by manufacturer. When mandrels are utilized to verify deflection of flexible pipe products, the Government will verify the mandrel OD through the use of proving rings that are manufactured with an opening that is certified to be as shown above.

c. Deflection measuring device: Shall be approved by the Contracting Officer prior to use.

d. Warranty period test: Pipe found to have a deflection of greater than allowable deflection in paragraph PLACING PIPE above, just prior to end of one-year warranty period shall be replaced with new pipe and tested as specified for leakage and deflection. Inspect 100 percent of all pipe systems under the travel lanes, including curb and gutter. Random

SECTION 33 40 00 Page 16 inspections of the remaining pipe system outside of the travel lanes shall represent at least 10 percent of the total pipe footage of each pipe size. Inspections shall be made, depending on the pipe size, with video camera or visual observations. In addition, for flexible pipe installations, perform deflection testing on 100 percent of all pipes under the travel lanes, including curb and gutter, with either a laser profiler or 9-fin mandrel. For flexible pipe, random deflection inspections of the pipe system outside of the travel lanes shall represent at least 10 percent of the total pipe footage of each pipe size. When mandrels are utilized to verify deflection of flexible pipe products during the final post installation inspection, the Government will verify the mandrel OD through the use of proving rings.

3.7.3 Post-Installation Inspection

Check each reinforced concrete pipe installation for joint separations, soil migration through the joint, cracks greater than 0.01 inches, settlement and alignment. Check each flexible pipe (HDPE, PVC, CMP, PP) for rips, tears, joint separations, soil migration through the joint, cracks, localized bucking, bulges, settlement and alignment.

a. Replace pipes having cracks greater than 0.1 inches in width or deflection greater than 5 percent deflection. An engineer shall evaluate all pipes with cracks greater than 0.01 inches but less than

0.10 inches to determine if any remediation or repair is required. RCP with crack width less than 0.10 inches and located in a non-corrosive environment (pH 5.5) are generally acceptable. Repair or replace any pipe with crack exhibiting displacement across the crack, exhibiting bulges, creases, tears, spalls, or delamination.

b. Reports: The deflection results and final post installation inspection report shall 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 systems, inspector notes, condition of joints, condition of pipe wall (e.g. distress, cracking, wall damage dents, bulges, creases, tears, holes, etc.).

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SECTION 33 40 00 Page 17

3.6.5 Determination of Density