CITY OF PHOENIX, ARIZONA

OFFICE OF THE CITY ENGINEER

DESIGN AND CONSTRUCTION PROCUREMENT

LIFT STATION 47 REDUNDANT FORCE MAIN

TECHNICAL SPECIFICATIONS

PROJECT NO. WS90501000

ISSUED FOR CONSTRUCTION

PREPARED BY

(For use with the 2026 Revision to the 2025 Edition of MAG Uniform Standard Specifications and Details for Public Works Construction and the 2024 City of Phoenix

Supplement to 2023 MAG Uniform Standard Specifications)

LIFT STATION 47 – REDUNDANT FORCE MAIN

MAG SPECIFICATIONS SECTION 607 TRENCHLESS INSTALLATION OF SMOOTH

WALL JACKING PIPE

Delete the title of this SECTION in its entirety and replace with the following:

PART 1 – GENERAL

A. SUMMARY

1. Section Includes:

1. Construction of pipe undercrossings.

2. Related Specification Sections include but are not necessarily limited to:

1. MAG Standard Specifications Section 602

B. SUBMITTALS

1. Shop Drawings:

1. Product technical data including:

a. Acknowledgement and letter of certification that products submitted meet requirements of standards referenced.

b. Manufacturer's installation instructions.

c. Compliance with submittal requirements of authority or agency having jurisdiction over undercrossing.

d. Welder certifications as applicable.

PART 2 – PRODUCTS

A. MATERIALS

1. Casing Pipe

1. Structural grade steel: Minimum yield strength of 35,000 psi or greater as required by the permits.

2. Wall thickness: Minimum thickness shall be 0.5 inches for all casing pipes 48 inches diameter and less and in accordance with MAG Standard Specifications Table 602-1 for all casing pipes greater than 48 inches.

3. Diameter: Minimum of 12 inches larger than outside diameter of carrier pipe's jointing system or size indicated on the plans, whichever is greater.

PART 3 – EXECUTION

A. INSTALLATION

1. General

1. Install undercrossing to meet requirements of authority or agency having jurisdiction over undercrossing.

2. Observe work requirements stipulated in any permit condition.

3. Consult Contract Drawings for limitation or required methodology of construction within right-of-way.

4. Should a different methodology than shown in the Contract

Drawings for the installation of casing pipes for utility crossings be desired, a substitution request must be provided.

B. If installation of crossing is by jacking or dry boring, the following will be required unless more rigid requirements are specified by the authority or agency having jurisdiction over the crossing:

1. Install undercrossing to meet requirements of authority or agency having jurisdiction over undercrossing.

2. Pressure grout all voids outside of casing, including abandoned or misaligned holes.

a. Provide a brick and mortar bulkhead at each end of the casing pipe a minimum of 8 inches thick.

b. Install watertight rubber pull on end seal.

c. Install pipe sleeve drains on either end of the casing pipe.

3. Undercrossing casing:

a. Full lengths.

b. Weld pressure tight.

4. After casing is installed, band casing spacers 120 degrees apart to each length of carrier pipe to prevent displacement and pull pipe into place.

a. Pipe must be straight and centered in casing when in place.

b. Pipe and spacers shall be installed per requirements shown in the Contract Drawings

MAG SPECIFICATIONS SECTION 611 WATER, SEWER AND STORM DRAIN

TESTING

Subsection 611.2.2 HYDROSTATIC TESTING: Delete this Subsection in its entirety and replace with the following, adopted from the City of Phoenix Supplement to

MAG:

The Contractor shall test waterlines for watertightness, including all fittings and connections. Each pipe shall be tested for leakage and pressure in accordance with applicable provisions of AWWA standards and/or manuals, except as modified below.

The Contractor shall provide all vents, piping, plugs, bulkheads, valves, bracing, blocking and pump, including measuring device and all other equipment necessary for making the tests.

The pipe shall be tested between the closed ends of the pipe. There shall be no testing against a valve unless otherwise approved. Pipe test section shall be limited to 2500 linear feet or less unless otherwise approved in writing by the Engineer. The new pipeline must be separated from any potable system in such a way as to prevent any potential for cross-contamination between the existing potable water system and the new pipeline.

The test shall be made after the backfilling is completed or compacted, regardless of the compaction method. All connections, blowoffs, hydrants and valves shall be tested with the main, where practical. The test section shall be slowly filled with potable water and all air shall be vented from the line. The rate of filling shall be as approved by the superintendent of water distribution, with at least 24-hour notice required before filling is scheduled.

(A) Pressure Tests: Force mains, including all fitting and connections, shall be tested for watertightness by subjecting each test section to pressure test.

The test pressure shall be measured at the lowest end of the test section.

The test pressure shall be 188 psi unless otherwise specified. The duration of each pressure test shall be at least 2 hours.

The pressure test shall begin after the pipe has been filled with water for at least 24 hours to allow for absorption.

(B) Leakage Tests: Leakage tests shall be made after pressure test has been completed, pressure test results are satisfactory, and all backfilling and compaction are completed.

The duration of each leakage test shall be at least 2 hours. Leakage test pressure shall be at least 150 psi, and the test pressure shall be maintained within 5 psi of the specified leakage test pressure during the test. Water may be continually fed or added when the pressure drops 5 psi.

The maximum allowable leakage from the pipeline shall be determined by the formula:

L= ND√P

in which:

L = Allowable leakage in gallons per hour N = Number of joints in the pipe being tested, with no allowance for joints at branches, blowoff, fittings, and similar appurtenances. “N” is calculated using the standard length of pipe installed divided into the length being tested.

D = Nominal inside diameter of pipe in inches P = Average test pressure, in psi gage, as measured at the lowest point in the test section Should the test on any section of the pipeline show leakage greater than specified above, the Contractor shall locate and correct until the leakage is within the specified allowance for a 2-hour duration.

All repairs and retests shall be at the Contractor’s expense.

Leakage is defined as the quantity of make-up water necessary for the test section to maintain the specified leakage test pressure after the pipeline has been filled with water and all air expelled.

All water must be dechlorinated to negligible levels prior to discharge to any location. Connections to existing pipelines or existing valves shall be made after new construction has satisfactorily passed both the pressure and leakage tests and potable water piping has been flushed and disinfected in accordance with Section 611.

Subsection 611.7 PAYMENT: Add the following as the third paragraph of this Subsection:

There will be no measurement and payment for sewer line testing. The Contractor shall include all associated costs in the unit bid price for sewer pipe installation.

MAG SPECIFICATIONS SECTION 702 BASE MATERIALS:

Delete this Subsection in its entirety and replace with the following, adopted from the City of Phoenix Supplement to MAG:

702.1 GENERAL

Base material (Select Material Type A, Select Material Type B, Aggregate Base ABC) shall be crushed aggregate, with gradation per Table 702-1.

The Contractor shall submit documentation to the Engineer from a city-approved testing laboratory showing compliance with Table 702-1 ten (10) days prior to placement of base material except where base materials are being obtained from an approved source that is on a list maintained by the City of Phoenix, Street Transportation Department, Design and Construction Management Division, Materials Lab Section.

RCM and RAP meeting the requirements of Section 702 may be utilized as base material with prior approval from the City of Phoenix Materials Lab.

Cement or lime treated base meeting the requirements of Section 702 may be utilized as base material, except within the pipe embedment zone around Reinforced Concrete Pipe (RCP) and metal pipe.

702.1.1 Aggregate Base Course is primarily used in roadway applications or where otherwise specified by project plans or special provisions.

702.1.2 Select Material is primarily used, as a subbase in roadways, fill and embankment applications or where otherwise specified by project special provisions.

702.2 PHYSICAL PROPERTIES

Crushed aggregate shall consist of crushed rock or crushed gravel or a combination thereof as defined in Section 701.

TABLE 702-1

SIEVE ANALYSIS

TEST METHODS AASHTO T-27, T-11

Sieve Size

Accumulative Percentage Passing Sieve, by Weight

Select Material Aggrega te Base Course

Type A Type B

3 in. 100 -- - -

1-1/2 in. -- 100 100

1 in. -- -- 90–100

No. 4 30–75 30–70 38–65

No. 8 20–60 20–60 25–60

No. 30 10–40 10–40 10–40

No. 200 0–12 0–12 3–12

Plasticity Index Test Methods AASHTO T-89 Method A, T-90, T146 Method A

Maximum allowable value 5 5 5

TABLE 702-1

SIEVE ANALYSIS

TEST METHODS AASHTO T-27, T-11

Fractured Face, One Face Test Method ARIZ 212, Percent by Weight of the Material Retained on a #4 Sieve

Minimum required value 50 50 50 Resistance to Degradation and Abrasion by the Los Angeles

Abrasion Machine Test Method AASHTO T-96, Percent Loss by Weight

Maximum allowable value at 100 revolutions

10 10 10

Maximum allowable value at 500 revolutions

40 40 40

CBR

Test Method AASHTO T-193

Minimum at 0.2000 inch penetration at 65 blows, 100% compaction

Friable or Deleterious Substances Test Method ASTM C-142, Percent by Weight

Maximum allowable in fine aggregate 3 3 3

Maximum allowable in coarse aggregate 3 3 3 Soundness

Test Method ASTM C-88, Percent Loss by Weight

Maximum allowable in fine aggregate 10 10 10

Maximum allowable in coarse aggregate 12 12 12 Apparent Specific

Gravity Test Method ASTM C-

Minimum (considering other factors) 2.65 2.65 2.65 pH and Resistivity Test Method ARIZ 236 pH 6–10 6–10 6–10

Minimum Resistivity 2000 ohm-cm 2000 ohm-cm 2000 ohm-cm

MAG SPECIFICATIONS SECTION 738 HIGH-DENSITY POLYETHYLENE PIPE AND

FITTINGS FOR STORM DRAIN AND SANITARY SEWER

Delete the title of this SECTION in its entirety and replace with the following:

HIGH-DENSITY POLYETHYLENE PIPE AND FITTINGS FOR STORM DRAIN AND

LIFT STATION FORCE MAINS

Delete this SECTION in its entirety and replace with the following:

738.1 GENERAL

738.1.1 Lift Station Force Mains: For all requirements related to HDPE pipe used on force mains serving wastewater lift stations, refer to the latest version of the Water Services Department Wastewater Lift Station Design Guidance Manual.

738.2 SYSTEM PARAMETERS

The polyethylene system working pressure rating accommodates the normal operating pressure and the repetitive surges. The pressure rating applies at 80 ℉ or less.

(A) Per AWWA C906, the repetitive surge pressure allowance is one half the pressure class of the pipe, and the occasional surge over pressure allowance is equal to the pressure class of the pipe. Allowable Total Pressure during Recurring Surge conditions equals 1.5 times the pipe’s pressure class.

Allowable Total Pressure during Occasional Surge conditions equals 2.0 times the pipe’s pressure class.

(B) The Pressure Class per AWWA C906, Pressure Rating and Allowable Total

Pressure during Recurring and Occasional Surge for PE4710 pipe are as follows:

1. Maximum Operating Temperature up to 80 ℉:

Pipe Dimension Ratio (DR)

Pressure Class / Rating

Allowable Total Pressure During Recurring Surge

Allowable Total Pressure During

Occasional Surge

DR 17 125 psi 188 psi 250 psi

2. Maximum Operating Temperature up from 81 to 90 ℉:

Ratio (DR)

Pressure Class / Rating

Allowable Total Pressure During Recurring Surge

Allowable Total Pressure During

DR 17 113 psi 170 psi 226 psi

3. Maximum Operating Temperature up from 91 to 100 ℉:

Ratio (DR)

Pressure Class / Rating

Allowable Total Pressure During Recurring Surge

Allowable Total Pressure During

DR 17 100 psi 150 psi 200 psi

4. Maximum Operating Temperature up from 101 to 110 ℉:

Ratio (DR)

Pressure Class / Rating

Allowable Total Pressure During Recurring Surge

Allowable Total Pressure During

DR 17 87 psi 131 psi 175 psi

738.3 DETAILS OF CONSTRUCTION

Polyethylene pipe shall be made from HDPE material having a material designation code of PE4710. The material shall meet the requirements of ASTM D 3350 and shall have a cell classification of PE445474C.

(A) The pipe and fittings shall meet the requirements of AWWA C906.

(B) Pipe and Fittings: HDPE Pipe shall be manufactured to pressure rating requirements of 100 psi at operating temperature of 80 ℉ or less. The outside diameter of the pipe shall be based on the DIPS sizing system.

(C) HDPE butt fusion fittings, flanges and mechanical joint adapters shall have a material designation code of PE4710 and a minimum Cell Classification as noted in 2.2.A. Fittings shall have a pressure rating equal to the pipe unless otherwise specified on the plans. All fittings shall meet the requirements of

AWWA C906.

1. Butt Fusion Fittings:

a. Fittings shall meet the requirements of ASTM D3261.

b. Markings for molded fittings shall comply with the requirements of

ASTM D 3261.

c. Fabricated fittings shall be marked in accordance with ASTM F 2206.

2. Flanged and Mechanical Joint Adapters:

a. Flanged and Mechanical Joint Adapters can be made to ASTM D 3261 or if machined, must meet the requirements of ASTM F 2206.

b. Markings for molded or machined flange adapters or MJ Adapters shall be per ASTM D 3261.

c. Markings for fabricated flange adapters shall be per ASTM F 2206.

(D) Van-Stone style, metallic (including stainless steel), convoluted or flat-plate, back-up rings and bolt materials shall follow the guidelines of Plastic Pipe Institute Technical Note #38, and shall have the bolt-holes and bolt-circles conforming to AWWA C207 Class 150 Series D.

1. The back-up rings shall have a radius on the inside diameter of the bore so as to be compatible with HDPE Flanges, HDPE pipe standard, and DR rating of the HDPE. Back up rings shall have bolt pattern that will mate with AWWA C207 Class D (or B or E), ASME/ANSI B 16.5 Class 150, ASME/ANSI B 16.1 Class 125, or ASME/ANSI B16.47 Series A.

2. The back-up ring shall provide a long-term pressure rating equal to or greater than the pressure-class of the pipe with which the flange adapter assembly will be used, and such pressure rating shall be marked on the back-up ring.

3. The back-up ring, bolts, washers and nuts shall be protected from corrosion by a system such as paint, coal-tar epoxy, wrapping tape system, polyether or polyester fusion bonded epoxy coatings, anodes, or cathodic protection..

4. As an EQUAL to coatings, back-up ring, bolts, washers and nuts can be alternately coated with a petroleum based mastic and wrapping tape system Denso Paste primer and Densyl Tape finish as manufactured by Denso, or approved equal. If Densyl Tape is used, polyethylene bagging is still required.

5. For all flanged connections, heavy hex bolts, Grade A193 B7 and heavy hex nuts, Grade A194 Grade 2H are required.

6. Flange assemblies shall be assembled and torque patterned according to PPI TN-38, “Bolt Torque for Polyethylene Flanged Joints.”

7. Mandatory re-torque applied 4-hours to 24-hours after completion of the initial torque application is required. This mandatory re-torqueing to the initial target torque after a 4-hour to 24-hour creep-relaxation period is done to compensate for possible bolt-creep, nut embedment, and gasket compression-set.

(E) Electro Fusion Fittings - Fittings shall be made of HDPE material with a minimum material designation code of PE 4710 and with a minimum Cell Classification as noted in 2.2.A. Electro Fusion Fittings shall have a manufacturing standard of ASTM F1055. Fittings shall have a minimum pressure rating equal to or greater than the pipe to which they are joined unless otherwise specified on the plans. For potable water systems, all electro fusion fittings shall have AWWA approval

1. Electro fusion is allowed only at the approval of the Engineer and the City.

(F) Fusion Requirements

1. All Fusion Equipment, whether new or used, rented or owned, shall comply with the requirements of ISO 12176-1 “Equipment for Fusion Jointing Polyethylene Systems”.

(G) Product and Manufacturer: Provide one of the following:

1. HDPE Pipe and Fittings:

a. JM Eagle.

b. ISCO.

c. Performance Pipe.

d. ASAHI/America.

e. Driscopipe.

f. WL Plastics.

g. Or equal.

2. HDPE Wall Anchors and Flange Adapters:

a. Improved Piping Products, Inc.

b. Or equal.

3. Backup Flanges:

a. Improved Piping Products, Inc.

b. Or equal.

4. Butt Fusion Equipment:

a. McElroy Manufacturing, Inc.

b. Or equal.

738.4 MARKING FOR IDENTIFICATION

(A) All pipe line materials shall be permanently marked with the following:

1. Name or trademark of manufacturer.

2. Pipe class and specification designation.

3. Pipe size, grade and type.

4. Date and place of manufacture.

5. Pipe schedule.

(B) All pipe shall be color coded for the intended service. The color coding shall be permanently co-extruded stripes on the pipe outside surface as part of the pipe’s manufacturing process. Painting HDPE pipe to accomplish color coding is not permitted. Color coding shall be as follows:

1. Sewer – gray

738.5 JOINING METHODS

(A) Butt Fusion:

1. The pipe shall be joined by the butt fusion procedure outlined in ASTM

F 2620 or PPI TR-33. All HDPE pipe shall be joined to itself by the heat fusion process which produces homogeneous, seal, leak tight joints.

Tie-ins between sections of HDPE pipe shall be made by butt fusion whenever possible.

2. All fusion joints shall be made in compliance with the pipe or fitting manufacturer’s recommendations.

3. Fusion joints shall be made by qualified fusion technicians per PPI TN- 42.

4. Internal and External beads shall be removed on the fused HDPE piping.

(B) Electro Fusion:

1. Electro fusion joining shall be done in accordance with the manufacturers recommended procedure. Other sources of electro fusion joining information are ASTM F 1290, PPI TN 34, and PPI Municipal Advisory Board (MAB) Generic Electro Fusion Procedure for Field Joining of 12 Inch and Smaller Polyethylene (PE) Pipe. The process of electro fusion requires an electric source, commonly called an electro fusion processor that has wire leads and a method to read electronically (by laser) or otherwise input the barcode of the fitting. The electro fusion processor must be capable of reading and storing the input parameters and the fusion results for later download to a record file. Qualification of the fusion technician shall be demonstrated by evidence electro fusion training within the past year on the equipment to be utilized for this project.

(C) Mechanical:

1. Mechanical connection of HDPE to auxiliary equipment such as valves, pumps, and fittings shall use mechanical joint adapters and other devices in conformance with the PPI Handbook of Polyethylene Pipe, Chapter 9 and AWWA Manual of Practice M55, Chapter 6.

2. All mechanical and compression fittings shall be recommended by the manufacturer for raw sewage use. When required by mechanical coupling manufacturer, pipe stiffeners shall be employed to support the interior wall of the HDPE. The stiffeners shall support the pipe’s end and control the “necking down” reaction to the pressure applied during normal installation. The pipe stiffeners shall be formed of 304 or 316 stainless steel, with a wedged style design to fit the HDPE manufacturers published average inside diameter of the specific size and DR of the

HDPE.

3. Mechanical couplings that wrap around the pipe and act as saddles are made by several manufacturers specifically for HDPE pipe. All such saddles, tapping saddles, couplings, clamps etc. shall be recommended by the manufacturer as being designed for use with HDPE pipe at the pressure class listed in this section.

4. Unless specified by the fitting manufacturer, a restraint harness or concrete anchor is recommended with mechanical couplings to prevent pullout.

(D) Joint Recording:

1. The critical parameters of each fusion joint, as required by the manufacturer and these specifications, shall be recorded by an electronic data logging device.

2. All fusion joint data shall be included in the Fusion Technician’s joint report.

738.6 INSTALLATION:

(A) Pipe Inspection:

1. All pipe and fittings shall be subjected to visual inspection at time of delivery and before they are installed or lowered into the trench to be laid.

Defective, damaged, or unsound pipe will be rejected. Cuts, punctures, or gouges that penetrate or reduce the wall thickness by 10% or more are not acceptable and must be removed and discarded. Joints or fittings that do not conform to these specifications will be rejected and must be removed immediately by the Contractor.

(B) Handling:

1. The handling of the pipeline shall be in such a manner that the pipe is not damaged by dragging it over sharp and cutting objects. Sections of the pipes with cuts and gouges exceeding 10% of the pipe wall thickness or kinked sections shall be removed and the ends rejoined.

2. Refer to the PPI Material Handling Guide for HDPE Pipe and Fittings for recommendations, guidelines and instructions regarding the handling, lifting, loading, storing and installing polyethylene pipe and fittings.

(C) Unions: Install dielectric unions wherever dissimilar metals are connected, except for bronze or brass valves in ferrous piping.

(D) Transitions from One Type of Pipe to Another: Provide all necessary adapters, specials and connection pieces required when connecting different types and sizes of pipe or connecting pipe made by different manufacturers.

(E) General Considerations before Installation: In slipline or pipe bursting rehabilitation applications, the deteriorated pipeline should be inspected by remote TV camera to locate structurally deteriorated areas, obstructions, offset and separated joints, undocumented bends, and service connections.

(F) Fusion Data Recording:

1. For 6” and larger pipe sizes, McElroy Data Logger or equivalent fusion data recorder shall be used to record all fusion welds on hydraulically operated fusion machines. The device shall be capable of meeting the requirements of ASTM F 3124, “Standard Practice for Data Recording the Procedure used to Produce Heat Butt Fusion Joints in Plastic Piping Systems or Fittings”. The device, or combination of devices, shall record the following variables of each fused joint:

a. Heater surface temperature immediately before inserting the heater plate. Alternatively, the heater plate may be measured with a pyrometer and entered into the weld record.

b. Gauge pressure during the initial heat cycle

c. Gauge pressure and elapsed time during the heat-soak cycle

d. Heater removal (dwell) time

e. Gauge pressure and elapsed time during the fusing/cool cycle

f. Drag pressure

g. Pipe diameter and wall thickness

h. Type of HDPE material (Specification and Classification) and manufacturer

i. Fusion Machine Identification

2. The device shall record the operator, a unique operator ID number, the date and time of each weld.

3. Records showing the device is up to date on all required calibration should be available for presentation when requested.

4. All fusion welds should be traceable to the report (via operator and weld

ID) with an indentation weld stamp or by permanent paint marker/pen next to fusion weld.

5. When requested prior to commencement of work, a weld location map may requested by the OWNER or ENGINEER.

(G) Butt Fusion Examination and Testing:

1. Examinations

a. Visual: For pipe sections, examine the full exterior circumference for bead uniformity before cutting. After cutting the pipe section, review the interior bead. All beads should have visually acceptable bead formation as shown in Fig 4 and Appendix X2 of ASTM F 2620. In addition, the following characteristics are expected:

i. There shall be no evidence of cracks or incomplete fusing

ii. There shall be no evidence of captured objects (e.g., pipe shavings, facer ribbons) between bonded surfaces.

iii. Variations in upset bead heights on opposite sides of the cleavage and around the circumference of fused pipe joints are acceptable.

iv. The apex of the cleavage between the upset beads of the fused joint shall remain above the base material surface

v. Fused joints shall not display visible angular misalignment, and outside diameter mismatch shall be less than 10% of the nominal wall thickness

vi. Fusion data record review that meet criteria of section 3.2. F.1 can be used as additional verification of visual indicators.

b. Mechanical Testing:

i. CONTRACTOR shall mechanically test the first fusion of each operator and each machine used on the project. If the operator or the fusion machine changes, the CONTRACTOR shall mechanically test the first fusion. Installation shall not continue until a fusion test has passed the test. Additional mechanical test are not required as long as long as the fusion are reviewed with the frequency specified in section 3.2.G.1.e.

ii. The fusion shall be allowed to cool completely, then fusion test straps shall be cut out.

iii. All samples shall be labeled with operator information. Testing must be done at 73 ℉ plus or minus 5 degrees or as approved by the ENGINEER. The test temperature and sample size are critical to testing. Testing performed at cold or elevated temperatures may not give similar results to tests performed at ambient temperatures.

iv. Each pipe sample weld shall be subjected to testing at two locations 180 degrees apart from each other in the joint weld. All specimens shall be tested by one of the following methods:

(a) Reverse Bend Test are allowed for pipe sizes 4” IPS or smaller. The specimens shall be removed and tested in accordance with ASTM F 2620, Appendix X4.

(b). Guided Side Bend Test are allowed for all pipe sizes 4” IPS and larger. The specimens shall be removed and tested in accordance to recommendations and procedures provided by McElroy Manufacturing.

v. Results of any mechanical test should be documented.

Information on the weld and operator should be transferred from the sample to the testing record.

c. Fusion Data Record Review The fusion date record for each fused joint shall be compared to the approved fusion procedure. The reviewer shall verify the following:

i. That all data required by section 3.2.F.1 was recorded

ii. Interfacial pressure was within the acceptable range

iii. Heater surface temperature was within the acceptable range

iv. Butt fusion pressure applied during the fusing/cool cycle was correctly calculated to include drag pressure, fell within the acceptable range for the applicable size and agrees with the recorded hydraulic fusing pressure.

v. Butt fusing pressure was reduced to a value less than or equal to drag pressure at the beginning of the heat soak cycle.

vi. Fusing machine was opened at the end of the heat soak cycle, the heater was removed, and the end were brought together at the fusion pressure with the acceptable time range

vii. Cooling time at butt fusing pressure met the minimum time specified

d. If the recorded data in section 3.2.G.1.c is outside the limits of the acceptable range, the joint is unacceptable.

e. Frequency. Records for test fusion joints should be reviewed immediately after the joint is completed. Fusion joints for jobsite fusions should be reviewed daily or before being covered with backfill, CLSM, or inserted into the existing force main.

738.7 WARRANTY

(A) Pipe and fitting suppliers shall provide a one-year warranty covering defects in product material and workmanship. A successful pressure test or pressure leak test prior to the expiration of the warranty period shall not relieve the supplier of warranty responsibility for the full warranty term.

(B) Fusion providers shall provide a one-year warranty from the date of installation acceptance covering defects in fusion joining workmanship that shall provide for remaking defective butt fusion, saddle fusion or electrofusion joints. A successful pressure test or pressure leak test prior to the expiration of the warranty period shall not relieve the installer of warranty responsibility for the full warranty term.

738.8 TESTING

(A) Hydrostatic pressure leak testing shall be conducted in accordance with

ASTM F2164. The section of pipeline to be tested must be restrained against any movement in the event of failure. The maximum duration of test is 8 hours. The maximum allowable test pressure for leak detection is 1.5 times the design pressure. See Plastic Pipe Institute (PPI) Hand book Chapter 2 for additional instructions

738.9 AIR RELEASE, AIR/VACUUM, AND COMBINATION AIR VALVES

(A) All valves listed below shall meet AWWA C512, latest edition, Standard for

Air-Release, Air/Vacuum and Combination Air Valves for Water Works Service.

1. Air / Vacuum Valves:

a. Purpose: Valve is used to automatically exhaust large quantities of air during pipeline filling, and to admit large quantities of air when the internal pressure drops below atmospheric.

b. Operation: Float actuated valve with large orifice exhausts or admits air from the system.

c. Design Conditions:

1) Air Discharge (Fill/Vent) Rate: 10 cfm @ 150 psi

2) Air Inlet Rate (Empty/Vacuum) Rate: 400 cfm @ 5 psi differential

d. Construction:

1) Manufacturer and Model:

a. ARI D-026, non-slam type

b. H-TEC Series 986 or approved equal

2) Body: Stainless Steel

3) Float: Type 316 Stainless Steel ASTM A240.

4) O-Ring: EPDM.

6) Trim: Type 316 Stainless Steel ASTM A240.

7) Inlet Size/Conn: Size and connection flanged unless otherwise shown on drawings.

8) Outlet Size/Conn: Size and connection (threaded, flanged, hooded) as shown on Drawings.

MAG SPECIFICATIONS SECTION 750 DUCTILE IRON WATER PIPE AND FITTINGS

Delete this SECTION in its entirety and replace with the following:

Subsection 750.1 DESCRIPTION:

(A) Scope:

1. Provide all labor, materials, equipment and incidentals as shown on the Drawings, specified and required to furnish ductile iron pipe and fittings.

Subsection 750.2 MATERIALS:

(B) Ductile Iron Pipe and Fittings:

1. Flanged Pipe: Fabricate in accordance with requirements of AWWA

C115.

a. Thickness: Wall thickness shall be minimum Class 53 except where the specified pressure requires heavier pipe.

2. Non-Flanged Pipe: Conform to AWWA C151 for material, pressure, dimensions, tolerances, tests, markings and other requirements.

3. Joints:

a. Flanged Joints: Conform to AWWA C110, C115 and C153 capable of meeting, working and test pressure.

1) Gaskets: High temperature resistant sealing compounds

(Loctite PST 592) or equivalent with Dimethacrylate ester base and Teflon can be used.

a) Gaskets: Unless otherwise specified, gasket stock shall be a synthetic rubber, 1/8-inch thick, full face, compound in which the elastomer is nitrile or neoprene. The compound shall contain not less than 50 percent by volume nitrile or neoprene and shall be free from factice, reclaimed rubber and other deleterious substances.

Gaskets shall comply with AWWA C111 for

b) ush-on and mechanical joints with AWWA C606 for grooved end joints.

2) Bolts and Nuts: Conform to ANSI B18.2.1 and ANSI B18.2.2, respectively. Exposed and buried bolts and nuts shall be ASTM A307, Grade B. Buried bolts and nuts not encased in polyethylene shall be mortar coated to a minimum thickness of 1-inch or alternately coated with a petroleum based mastic and wrapping tape system Denso Paste primer and Densyl Tape finish as manufactured by Denso, or equal. Submerged bolts and nuts shall be Type 316 stainless steel.

3) Mechanical Joints: Conform to AWWA C110, AWWA C111 and C- 153.

4) Glands: Ductile iron.

5) Gaskets: Plain Tip.

6) Bolts and Nuts: Conform to ANSI B18.2.1 and ANSI B18.2.2, respectively. Bolts and nuts shall be ASTM A307, Grade B.

Buried bolts and nuts not encased in polyethylene shall be mortar coated to a minimum thickness of 1-inch or alternately coated with a petroleum based mastic and wrapping tape system Denso Paste primer and Densyl Tape finish as manufactured by Denso, or equal.

b. Push-On Joints: Conform to AWWA C111.

1) Gaskets: Molded rubber.

2) Strips: Each plain end shall be painted with a circular stripe to provide a guide for visual check that joint is properly assembled.

c. Grooved End Joints: Conform to AWWA C606.

1) Gaskets: Flush seal type designed for ductile iron.

2) Bolts and nuts: As specified for flanged joints.

3) Unless otherwise specified, grooved end couplings shall be rigid joint for exposed service and flexible joint for buried service.

4) Grooved end joints shall be as manufactured by one of the following:

a) Victaulic, Style 31

b) Or equal.

5) For grooved-end pipe, wall thickness shall be minimum Class 53 except where the specified pressure requires heavier pipe.

d. Restrained Joints: Restrained push-on joints shall be capable of being deflected after full assembly. Joint assembly shall be in strict conformance with AWWA C600 and manufacturer’s recommendations. No field cuts of restrained pipe are permitted without prior approval of the ENGINEER.

e. Restrained Joints:

1) Restrained joints for mechanical joint piping shall be one of the following:

a) Romagrip, as manufactured by Romac Industries.

b) Megalug, Series 1100, as manufactured by EBBA Iron Sales, Inc.

c) Stargrip, Series 3000, as manufactured by Star Pipe Products

d) Uni-Flange Series 1400, as manufactured by Ford Meter Box.

2) Restrained joints for push-on joint piping shall be one of the following:

a) Clow Super-lock Joint Pipe, as manufactured by Clow Cast Iron Pipe and Foundry Division of Clow Corporation.

b) Lok-Ring Joint, or Flex-Ring Joint, as manufactured by American Cast Iron Pipe Company.

c) TR Flex Joint, as manufactured by U.S. Pipe.

d) Thrust-lock, as manufactured by Pacific States Pipe.

e) Snap-Lok or Bolt-Lok, as manufactured by Griffin Pipe.

3) Split restrained joint glands for mechanical joints, or wedge action restrained joint glands for push (non-mechanical) joints, are only allowed for connection or repair to existing installed pipe. The split restrained joint or wedge glands shall be one of the following:

a) Stargrip Series 3000S, 3100P, 3100S, as manufactured by Star Pipe Products

b) Megalug Series 1100SD, 1100H D, as manufactured by

EBAA Iron Sales, Inc.

c) Megalug Series 1700, as manufactured by EBAA Iron Sales, Inc.

d) Uni-Flange Series 1450, as manufactured by Ford Meter Box

(C) Specials:

1. Transition Pieces:

a. Furnish suitable transition pieces (adapters) for connections to existing piping.

b. Unless shown on Drawings, expose existing piping to determine material, dimensions and other data required for transition pieces.

Subsection 750.4 COATINGS AND LININGS

(A) Unless otherwise specified, pipe and fittings shall be lined with a cement-mortar lining in accordance with AWWA C104.

(B) Buried pipe and fittings shall be coated on the outside with a bituminous coating, approximately 1-mil thick material as specified in AWWA C151. Buried flanged joints shall be coated with a petroleum based mastic and wrapping tape system Denso Paste primer and Densyl Tape finish as manufactured by Denso, or approved equal. Color selection shall be submitted for owner’s approval.

Exposed pipe shall be prime coated and finish coated with the following:

1. Primer (Polyamidoamine Epoxy *)

a. Tnemec Series L69 Hi-Build Epoxoline II; 1 coat; 4-6 mils DFT

2. Finish Coat (Polyamidoamine Epoxy)

a. Tnemec Series L69 Hi-Build Epoxoline II; 1 coat; 4-6 mils DFT

(C) Polyethylene Encasement:

1. All polyethylene film shall be manufactured in accordance with

ANSI/AWWA

C105/A21.5.

2. All open cut installed buried pipe shall be provided with polyethylene encasement to prevent contact between the pipe and surrounding bedding material and backfill.

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

Subsection 750.5 EPOXY LINING MATERIAL

All ductile iron piping shall be epoxy lined. The material shall be an amine cured novalac epoxy containing at least 20 percent by volume of ceramic quartz pigment. Epoxy lining material manufacturer shall demonstrate a successful history of lining pipe and fittings for sewer service and submit a test report verifying the following properties, and a certification of the test results.

(A) A permeability rating of 0.00 when tested according to Method A of ASTM E- 96-66, Procedure A with a test duration of 30 days.

(B) The following test shall be run on coupons from factory lined ductile iron pipe:

1) ASTM B-117 Salt Spray (scribed panel): Results to equal 0.0 undercutting after two years.

2) ASTM G-95 Cathodic Disbondment 1.5 volts at 77°F: Results to equal no more than 0.5 mm undercutting after 30 days.

3) Immersion Testing rated using ASTM D-714-87.

a. 20 percent Sulfuric Acid: No effect after two years.

b. 25 percent Sodium Hydroxide: No effect after two years.

c. 160°F Distilled Water: No effect after two years.

d. 120°F Tap Water (Scribed panel): 0.0 undercutting after two years with no effect.

(C) An abrasion resistance of no more than four mils loss after one million cycles - European Standard EN 598: 1994 Section 7.8 Abrasion Resistance.

(D) Interior of the pipe shall receive 40 mils dry film thickness.

(E) Applicator: The lining shall be applied by a competent firm with a successful history of applying linings to the interior of ductile iron pipe and fittings.

(F) Surface Preparation: Pipe surfaces shall be cleaned and sand blasted prior to lining application in accordance with manufacturer’s recommended procedures.

(G) Inspection and Certification:

1) All ductile iron pipe and fitting linings shall be checked for thickness using a magnetic film thickness gauge. The thickness testing shall be done using the method outlined in SSPC-PA-2 Film Thickness Rating.

2) The interior lining of all pipe barrels and fittings shall be tested for pinholes with a non-destructive 2,500 volt test. Any defects found shall be repaired prior to shipment.

3) The pipe or fitting manufacturer shall supply a certificate attesting to the fact that the applicator met the requirements of this specification.

(H) Product and Manufacturer: Provide one of the following:

1) Protecto 401.

2) Or equal.