atlantic concrete products, inc. · 2020. 2. 16. · atlantic concrete products, inc. po box 129,...

ATLANTIC CONCRETE PRODUCTS, INC.

PO Box 129, 8900 Old Route 13, Tullytown PA 19007‐7129 Tel (215) 945‐5600 Fax (215) 946‐3102

Find this catalog and more on our website. www.AtlanticConcrete.com

Email: [email protected]

ATLANTIC CONCRETE PRODUCTS, INC.

PO Box 129, Tullytown PA 19007‐7129

Dear Sir or Madam,

I would like to introduce the individuals in our company who can be of assistance to you. Their positions, phone numbers and fax numbers are as follows:

Sales and Service: (215) 945‐5600 Jerry Donahue Sales Manager (215) 946‐3102 FAX Barry Sullivan Sales Representative

Production and Deliveries: (215) 945‐4990 Bill Watson Production Manager (215) 945‐9336 FAX Ken Van Bramer Shipping Manager Chris Long Production Administrator

Accounts Receivable / Credit and Collections: (215) 945‐5600 Steve Schlussel Billing Administrator (215) 945‐5016 FAX

Our street address is 8900 Old Route 13 (Bristol Pike), Tullytown PA 19007‐0098

Respectfully Yours, ATLANTIC CONCRETE PRODUCTS, INC.

Gerald J Donahue Sales Manager

A-LOK Products, Inc. and Tru-Contour have joined forces to bringtogether the best in secondary precast inverts available today. TheTru-Contour Invert Forming System offers the manhole producer avery durable, systematic and versatile method of forming all invertconfigurations from 4" through 48" diameter.

TRU-CONTOURTRU-CONTOUR

KEY ADVANTAGES

Two, three, and four way configurations including dead endcombinations with a standard .2 ft. of elevation difference (fall) canbe made easy and rapidly without the need for skilled labor.

Greater fall can be obtained based on the operators' ability toexperiment. The system's versatility is due to an unlimitedcombination offour basic wedges. With the combination of one or more of thesewedges, any angle can be obtained within 1.5 degrees. This allowsenough flexibility to effectively form an invert which aligns perfectlywith the entering pipeline.

System also available in Single Piece construction.

The Tru-Contour system cuts costly labor both in set-up and concretefinishing time. A basic three way can be set up in approximatelyfifteen minutes and depending on pouring procedures, can allow anaverage of four inverts per day to be formed from a single system.Finishing time is kept to a minimum due to the accuracy of flows theforms create. Each invert in regard to channel width, depth and radialturn is form finished.

SECONDARY INVERT FORMING SYSTEM

The Company With ConnectionsThe Company With Connections®

AVAILABILITY CHART

SIZE(IN/DIA.) 2-WAY 3-WAY 4-WAY

4" • • •6" • • •8" • • •

10" • • •12" • • •15" • • •18" • • •21" •24" •27" •30" •36" •42" •48" •

The Tru-Contour standard system allows for 2/3 invert depth and iscompatible with a variety of flexible pipe to manhole connectors. Fulldepth systems are also available.

The Tru-Contour assembly consists of:1) A hole adapter which is designed to align the invert assembly with

the flexible pipe to manhole connector. This insures pipe to invertcompatibility.

2) A series of 4 wedges and straight sections which when combinedprovides an unlimited selection of angles to create enoughflexibility to form an in invert within 1.5 degrees.

3) A stabilizing jack which prevents from floatation during castingoperations. This insures that correct fall is maintained across themanhole base.

Patent #4,484,724

INSTALLATION INSTRUCTIONS

#2 ASSEMBLE SMALLEST ANGLE WITHCENTERING ADAPTOR

A•LOK PRODUCTS INCORPORATED P.O. BOX 1647 • 697 Main Street • Tullytown, PA 19007 • www.a-lok.com • email: [email protected] • 215-547-3366 • 215-547-5260 FAX

ANY QUESTIONS REGARDING TRU-CONTOUR INSTALLATION, PLEASE CALL 1-800-822-2565

#1 ASSEMBLY STARTS WITH CENTERINGTRIANGLE IN LOW HOLE

#3 SMALLEST ANGLE ASSEMBLE IN LOWHOLE AND UPSTREAM SIDE.

#5 POSITION HUBS

#4 POSITION ANTI FLOTATION BAR ANDADDITIONAL CHANNEL

#6 COMPLETED THREE-WAY ASSEMBLYREADY TO POUR

The A•LOK STM is aflexible pipe-to-man-hole connectordesigned for the pre-vention of soil andwater infiltration intostormwater sewersystems. It can beused with both roundand elliptical shapedpipes and curved andflat wall structures. Itis available for 8"diameter and largerpipes.

A•LOK STMA•LOK STM

The standard connector is extruded from a polyisoprene compoundengineered to conform with the requirements outlined in section4.1.1 of ASTM C-1478 “Standard Specification for Storm DrainResilient Connectors Between Reinforced Concrete Storm SewerStructures, Pipes, and Laterals”. Alternative compounds are avail-able for unusual applications upon special order.

KEY ADVANTAGESThe A•LOK STM Connector functions on pure compression, makingfield installation quick and easy. Just clean and lubricate the connectorand pipe, center the pipe in the connector, and insert. This rapid instal-lation permits immediate backfilling, enhancing project safety and over-comes the normal problems encountered with water, running sand andother unstable trench conditions. This results in shorter job projections,while mininizing traffic interruption and cost overruns.

The A•LOK STM provides up to 10° of omnidirectional deflection whilestill maintaining a watertight seal. This design allows the connector tocompensate for shear due to settlement or ground movement preventingwater and soil infiltration into the sewer system. This proper pipe-to-structure connection minimizes the chance of pothole formation andsediment build-up in the storm system, saving states and municipalitiesmoney over the life of the structure.

On larger diameter pipe when size prohibits a gasket from being installedin a flat plane, an A•LOK STM Connector can be configured for castingin a curve with the connector staying perpendicular to the center line ofthe pipe. This design has resulted from years of extensive research anddevelopment and causes no loss of compression or deflection.

PERFORMANCE STANDARD

PIPE TO STRUCTURE CONNECTOR FOR STORMWATER SYSTEMS


The A•LOK STM meets or exceeds all material and test requirementsof ASTM C-1478: “Standard Specification for Storm DrainResilient Connectors Between Reinforced Concrete Storm SewerStructures, Pipes, and Laterals”.

See following chart:

MATERIAL

PRODUCT REFERENCESA.) ASTM C-1478Standard Specification for Storm Drain Resilient ConnectorsBetween Reinforced Concrete Storm Sewer Structures, Pipes,and Laterals.

B.) ASTM C-1244Standard Test Method For Concrete Sewer Manholes by the Negative Air Pressure (Vacuum) Test

C.) ASTM C-478Standard Specification for Precast Reinforced Concrete Manhole Sections

Copyright ASTM INTERNATIONAL. Reprinted with permission

TEST RESULTS ASTM METHODChemical resistance D 543

1 N Sulfuric acid no weight loss at 22°C for 48h1 N Hydrochloric no weight lossAcid

Tensile strength 1200 psi or D 4128.5 MPa, min

Elongation at break 350% min.

Hardness ±5 from mfg’s. D 2240specified hardness (Shore A

durometer)

Accelerated decr. of 15%, D 573,oven-aging max. of original 70±1°C for

tensile strength, 7 daysdecr. of 20%max. of elongation

Compression set decr. of 25%, D 395, Method B,max. of original at 70°C for 22hdeflection

Water absorption increase of 10%, D 471, immersemax. of original 0.75 by 2-in. orby weight 19 by 25-mm

Specimen indistilled waterat 70°C for 48h

Ozone resistance rating 0 D 1171

Low-temp no fracture at D 746brittle point -40°C

Tear resistance 200 lbf/in. D 624, Method Bor 34 kn/m

RESILIENT MATERIAL TEST OF ASTM C-1478

MT

PART 6 • DIMENSIONAL DATA

A•LOK STM Cross Section /Pipe Size OD’s

93 Series8.50" - 29.00"

94 Series30.00" - 59.50"

95 Series60.00" - 87.50"

Larger Sizes AvailableUpon Special Request

MAX. PIPE SIZE OD’s

Manhole 135° - 225° 90°Diameter Pipe Angle Pipe Angle

42” 26.5” 22.0”48” 31.5” 25.0”60” 42.0” 32.0”72” 52.5” 38.0”84” 59.5” 44.0”96” 73.5” 50.0”108” 76.0” 56.0”120” 85.0” 62.0”

PRODUCT SPECIFICATIONSA flexible pipe to manhole connector shall be used whenever a pipe penetrates into a precast concrete manhole or structure used in a stormwaterdrainage system.

The connector shall be the A•LOK® STM CONNECTOR as manufactured byA•LOK PRODUCTS, INC., Tullytown, PA, or approved equal.

The design of the connector shall provide a flexible, watertight seal between the pipeand concrete structure. The connector shall assure that a seal is made between:

(1) The connector and the structure wall by casting the connector integrally with the structure wall during the manufacturing process in a mannerthat it will not pull out during pipe coupling. The connector shall also be capableof being cast into a round structure by curving the connector in a manner thatallows it to remain centrally located within the structure wall and perpendicularto the pipe. This configuration will result in no loss of seal or deflection of pipeentering a concrete structure.

(2) The seal between the connector and the pipe shall be made by the compres-sion of the connector between the outside circumference of the pipe and the inte-rior hole opening of the structure. The connector shall be the only component toaffect the seal between the pipe and structure.

The connector shall be made from materials that conform to the physical andchemical requirements outlined in Section 4, “Materials and Manufacture” ofASTM C-1478 “Standard Specification for Storm Drain Resilient ConnectorsBetween Reinforced Concrete Storm Sewer Structures, Pipes, and Laterals,” andthe overall design will meet or exceed Section 7, “Test Methods andRequirements” of ASTM C-1478.

The connector shall be sized specifically for the type of pipe being used and shallbe installed in accordance with the recommendations of the manufacturer.

STEP 1:Confirm that the pipe surface is smooth, cleanand free of foreign materials, chips, gouges andform seams due to manufacturing or handling.Slightly bevel any sharp or blunt edges caused bythe cutting of the pipe.

STEP 2:Lubricate the connector and the entire sectionof the pipe that will be inserted into the connec-tor. The chart below lists A-LOK’s minimumlubrication length “L”.

STEP 3:Center the pipe and connector square to each otherand insert the pipe into the connector using abar or back hoe depending on the size. Oncethe pipe is coupled with the connector, deflect thestructure or pipe to achieve the proper angle.

WARNINGTo ensure the A-LOK STM Connector remains aflexible watertight connector, it is A-LOKProducts, Inc. strong recommendation that nomortar be placed between the pipe and wall ofthe concrete structure. The use of mortar in thisarea would decrease the effectiveness of the con-nector to compensate for shear caused by settle-ment or ground movement.

NOTE:To find approximate subgrade, measure from theoutside base of the structure to the junction of theconnector and flat spot. Then add the wall thick-ness of the pipe plus 1/4 inch.

CAUTION:When installing pipestubs for future pipelineinstallation, all stubsmust be properlyrestrained to prevent anymovement by meansother than the A-LOK STM Connector.

PIPE SIZE MIN. LUBRICATION LENGTH “L”4” - 15” 12”16” - 18” 18”

21” & Larger 24”



MAX. PIPE SIZE OD’sBOX STRUCTURES

Inside Wall Straight 90°Dimension Through Pipe Angle

2' 19.50” 17.50”3' 32.00” 30.00”4' 44.00” 42.00”5' 56.00” 54.00”6' 67.00” 65.00”7' 80.50” 78.50”8' 91.25” 89.25”9' 103.25” 101.25”

ANY QUESTIONS REGARDING A•LOK STM CONNECTORINSTALLATION, PLEASE CALL 1-800-822-2565

The RevolutionaryG3 Band makesinstallation into astructure simpleand fast. Just installthe connectorperpendicular to thehole and tighten thestainless steel nut. Asthe nut is tightened, acompressive force isapplied to the G3band ends, causingthem to slide pasteach other intostraight alignment.This movementincreases the bandsoverall circumferenceand compresses theconnector against theopening in the structure wall, creating a watertight seal. To insurethe best seal, place the bolt in the 12 o’clock position of the holeopening and tighten the nut to the specified torque value.

G3 BOOT SYSTEMA•LOK G3 BOOT SYSTEM

The connector shall be made from materials that conforms to thephysical and chemical requirements outlined in Section 4, “Materialsand Manufacture” of ASTM C-923 “Standard Specification forResilient Connectors Between Reinforced Concrete ManholeStructures, Pipes, and Laterals”, and the overall design will meet orexceed Section 7, “Test Methods and Requirements” of ASTM C-923.

The connector shall be sized specifically for the type of pipe beingused and shall be installed in accordance with the recommendationsof the manufacturer.

The G3 Boot System can withstand 15° of omnidirectionaldeflection and ½” of centerline offset while still maintaining awatertight connection. This flexibility eliminates infiltration due topipe shear caused by settlement or ground movement.

The inner O-ring design of the G3 Connector eliminates rubberwrinkling, compensates for pipe irregularity and wall thickness toinsure a watertight seal.

G3 Component Packaging, featuring a tough loop lock fastenerthat keeps installation instructions, take down clamp, boot andband secure together from factory to job site.

PRODUCT SPECIFICATIONS

PIPE TO MANHOLE CONNECTOR FOR SANITARY OR STORMWATER SYSTEMS


A flexible pipe to manhole connector shall be used whenever a pipepenetrates into a precast concrete manhole or structure.

The connector shall be the G3 Boot System featuring componentpackaging as manufactured by A•LOK PRODUCTS, INC.,Tullytown, PA, or approved equal.

The design of the connector shall provide a flexible, watertight sealbetween the pipe and concrete structure. The connector shallassure that a seal is made between (1) the connector and thestructure wall by placing the connector and expansion band intothe center third of the concrete hole opening. The band is thenexpanded by tightening the expansion mechanism increasing thebands overall circumference and compressing the connectoragainst the sides of the hole opening. (2) The seal between theconnector and the pipe shall be made by compressing theconnector against the outside circumference of the pipe by meansof a stainless steel take-down band.

MATERIAL

KEY ADVANTAGES


G3 BOOT SIZE LISTPIPE O.D.

ITEM RANGEMin.-Max.

G3-0804 3.50”-4.50” 8”G3-1206 6.0”-6.875” 12”G3-1208 8.0”-9.5” 12”G3-1410 10.0”-11.25” 14”G3-1612 12.0”-13.5” 16”

HOLESIZE

G3 BOOT SYSTEMWITH

COMPONENT PACKAGINGAND TORQUE WRENCHES

G3 Boot System meets or exceeds requirements of ASTM C-923

PRODUCT REFERENCES


WARNING: To ensure the G3 Boot System remains a flexible watertight connector, itis A•LOK Products, Inc. strong recommendation that no mortar be placed betweenthe pipe and wall of the concrete structure. The use of mortar in this area woulddecrease the effectiveness of the connector to compensate for shear caused bysettlement or ground movement.

NOTE: A•LOK strongly suggests use of proper torque wrenches to secure the G3Boot in the structure as well as to secure the takedown clamp around theconnector and pipe. Both torque wrenches are available through A•LOK Products,Inc.

CAUTION: When installing pipe stubs for future pipeline installation, all stubs mustbe properly restrained to prevent any movement by means other than the G3Connector.

ANY QUESTIONS REGARDING G3 BOOT SYSTEM, PLEASE CALL 1-800-822-2565

1) Position G3-1208 Boot &Band in hole,then tighten to25 ft-lbs usingtorque wrench.

INSTALLATION INSTRUCTIONSPERFORMANCE STANDARD

3) For outsidemount: pull pipeback, repositionpipe within thewall and affixclamp directlybehind O-ring.Torque to 60 in-lbs and backfill.

2) Insert pipe intorolled inconnector. Forinside mount,affix clampbehind O-ring.Torque to 60in-lbs andbackfill.


TEST RESULTS ASTM METHODChemical resistance

1 N Sulfuric acid no weight loss D 543,1 N Hydrochloric no weight loss at 22°C for 48h

acid

Tensile strength 1200 psi, min. D 412


HardnessB ±5 from mfg’s. D 2240specified hardness (Shore A durometer)







Low-temperature no fracture at D 746brittle point -40°C

Tear resistance 200 lbf/in. D 624, Die B

ASTM C-923 Section 4.1RESILIENT MATERIALS TESTS

The A•LOK BOLT SLOT INSERT is a slotted insert designed to becast into the conical or slab top section of underground concretestructures for the purpose of anchoring the cast iron frame to thestructure. The insert assembly consists of a tough polypropylene shelland a .75 inch square galvanized nut.

The key purpose of the insert is to allow for center to center adjust-ment of the .75 inch galvanized nut to match the bolt center of themanhole frame. Traditional anchoring inserts require precise position-ing on center to assure proper alignment of assembly. With the avail-ability of the Bolt SLot Insert in overall lengths of 3 inches and 6 inch-es, any manhole frame can be accommodated regardless of bolt cen-ters.

The inserts are shipped assembled for standard installation into theprecast top section.

Inserts are held in position during the casting operation by a Four-Way Installation Holder in the four quadrants on a predeterminedcenter to allow maximum adjustment in matching the bolt center ofthe manhole frame.

BOLT SLOT INSERTA•LOK BOLT SLOT INSERT

The insert is molded from a copolymer polypropylene compound. The.75 inch square nut is galvanized.

KEY ADVANTAGES

• Guaranteed alignment of galvanized nut and bolt centers of man-hole frame.

• The .75 inch square nut is galvanized to prevent corrosion.

• In traffic areas, misalignment of frame and structure top is elimi-nated due to shifting or movement during construction, or duringroutine maintenance.

• In easement areas, the frame assembly is protected against theftor vandalism by being firmly secured to the structure.

• Precast top sections can be standardized to accept any manholeframe regardless of bolt centers.

SLOTTED INSERT TO ANCHOR CAST IRON FRAME TO STRUCTURE


MATERIAL

PRODUCT REFERENCES

A.) ASTM C-1244Standard Test Method For Concrete Sewer Manholes by the Negative Air Pressure (Vacuum) Test

B.) ASTM C-478Standard Specification for Precast Reinforced Concrete Manhole Sections

C.) FEDERAL REGULATIONCODE RR-F-621

Specification for Frame, Covers, Gratings, Steps,Sump Catch Basins, Manholes


INSERTPART ADJUSTMENT

NUMBER LENGTH CAPABILITY3 BOLT 3.125” 1.50”4 BOLT 4.125” 2.00”6 BOLT 6.125” 3.00”

MT

INSTALLATION INSTRUCTIONSPLANT INSTALLATION

1. Load Four-Way Installation Holder by sliding the (4) A•LOK BOLTSLOTS on to the Pads. Position each insert alike on the Pads toassure uniform placement in the precast section.

2. Pour concrete in form to desired level, and then press loadedFour-Way Installation Holder into concrete keeping common cen-ter of holder and core opening properly aligned.

3. When loaded holder and inserts have reached their proper posi-tion, use trowel to place concrete around inserts and finish toparea.

4. When concrete has hardened, Four-Way Installation Holder andPads can be removed.

TYPICAL BOLT SLOT DETAIL


ANY QUESTIONS REGARDING A•LOK BOLT SLOT INSERT INSTALLATION, PLEASE CALL 1-800-822-2565

TYPICAL WATERTIGHT ASSEMBLY(WITH GRADE WORK)

TYPICAL WATERTIGHT ASSEMBLY(WITH NO GRADE WORK)

FIELD INSTALLATION

1. Prior to placing the grade rings and manhole frame on the con-crete structure, the sealing tab is removed from the top of theA•LOK BOLT SLOT to gain access to the .75 inch square nut.

2. An all thread rod is then threaded into .75 inch nut and adjustedto the proper center to match frame.

3. After the grade work and frame are in place, the top nuts areinstalled and tightened and excess rod is cut off.

3", 4" or 6" BOLT SLOT

FLEX-LOK STEP INSERTA series of polypropylene inserts for the purpose of securing steps inthe wall of a precast concrete manhole or other concrete structure.

BENEFITS:

• Placement of insert is done at the time of manufacture.

• Concrete wall remains watertight.

• Guaranteed alignment and projection of steps.

• Precise hole to accept step shank.

• Interference fit makes installation of step rapid and simple.

• Polypropylene offers excellent chemical resistance.

The Company With Connections

697 Main Street • P.O. Box 1647 • Tullytown, PA 19007Toll Free: 1.800.822.2565 • Phone: 1.215.547.3366Fax: 1.215.547.5260 • www.a-lok.com

SPECIFICATIONS:

• Insert meets the requirements of ASTM C-478 section 16.

• Exceeds the performance test procedures of ASTM C-497 section 10.

SQUARE INSERTS

ROUND INSERTS

RIBS SECURE STEPSIN PLACE

The INSERTA•LOK™ Pipe toManhole Connector andINSERTA•LOK MD LateralConnector are flexible connec-tors specifically engineered toproduce a positive watertightseal for pipes entering precastconcrete structures and thestructure itself. TheINSERTA•LOK Connectors aremanufactured to meet or exceedthe requirements set forth inASTM C-923 titled “ResilientConnector Between ReinforcedConcrete Structures and Pipe.”

INSERTA•LOK™A•LOK INSERTA•LOK™

The connector is extruded from a compound formulated for waste-water applications and engineered to conform with the ResilientMaterial Requirements of section 4.1.1. Alternative compounds areavailable for unusual applications upon special order.

KEY ADVANTAGESThe INSERTA•LOK Connectors function on pure compression makingfield installation quick and easy. Clean and lubricate both connectorand pipe, center pipe in connector, and insert.

The connector provides a tapered profile which enhances couplingcharacteristics by allowing final compression to be gradual, therebyreducing the overall coupling force.

The INSERTA•LOK Connectors can be installed in a precision cast orcored opening as a mainline connector for new construction, a retro-fit or a tie in for new construction.

The connector assures a positive watertight connection providing over7 degrees of omnidirectional deflection to eliminate infiltration andshear due to settlement or ground movement. This flexibility permitsimmediate backfill enhancing project safety, and overcoming theproblems normally encountered with water, running sand and otherunstable trench conditions.


PIPE-TO-MANHOLE AND LATERAL CONNECTORS


The INSERTA•LOK Connectors meets or exceeds all material andperformance requirements of ASTM Standard C-923 titled “ResilientConnectors Between Reinforced Concrete Manhole Structures andPipes.”

MATERIAL

PRODUCT REFERENCES

A.) ASTM C-923Resilient Connector Between Reinforced Concrete Manholes Structures and Pipe.


C.) ASTM C-478CStandard Specification for Precast Reinforced Concrete Manhole Sections


TYPE OF PIPE Nominal Inserta•LOK Inserta•LOK MDPipe O.D. HOLE SIZE HOLE SIZE

4” P VC SDR 35 4.25” — 5.00”4” PVC SDR 40 4.50” — 5.25”4” DUCTILE 4.75” — 5.50”6” PVC SDR 35 6.25” — 7.00”6” DUCTILE 6.875” — 7.625”8” PVC SDR 35 8.50” 10.00” 9.25”8” DUCTILE 9.00” 10.50” 9.75”10” PVC SDR 35 10.50” 12.00” 11.50”10” DUCTILE 11.25” 12.50” 12.00”12” PVC SDR 35 12.50” 14.00” 13.25”12” DUCTILE 13.00” 14.50” 13.75”

INSERTA•LOK™FOR SANITARY MANHOLES ROUND AND FLATWALL

FOR LATERAL CONNECTORS YOU MUST USEMD INSERTA•LOK WITH 2 STAGE CORE BIT

PRODUCT SPECIFICATIONSA flexible pipe to manhole connector shall be used for sanitary anddrain pipe penetrations into precast concrete manholes and struc-tures.

The connector shall be the INSERTA•LOK™ CONNECTOR as man-ufactured by A•LOK PRODUCTS, INC., Tullytown, PA, or approvedequal.

The design of the seal shall provide a flexible, positive watertight con-nection between the pipe and concrete wastewater structures. Theconnector shall assure that a seal is made between (1) the connec-tor and the structure wall, and (2) between the connector and thepipe. The seal between the connector and the structure wall will bemade by pure compression of the resilient material against the wallof the structure. The seal between the connector and the pipe will bemade by pure compression of the resilient material against the out-side diameter of the pipe. The connector shall be the only componentto affect the seal between the pipe and structure.

The connector shall be extruded and vulcanized from materialswhose physical/chemical properties meet or exceed thephysical/chemical resistant properties outlined in ASTM C-923.

The connector shall be of size specifically designed for the pipe mate-rial being used and shall be installed in accordance with the recom-mendations of the manufacturer.






durometer)







Low-temperature no fracture at D 746brittle point -40°C



RESILIENT TEST REQUIREMENTS OF A.S.T.M. C-923

INSTALLATION OF CONNECTOR INTO WALL



WARNING: To ensure the INSERTA•LOK™ Connector remains a flexible, watertight joint, it is A•LOK Products, Inc. strong recom-mendation that no mortar be placed between the pipe and wall of the precast concrete unit. The use of mortar in this area wouldeliminate the flexibility for which the connector was designed and cause problems of shear.

NOTE: Approximate subgrade of trench at the structure can be determined by measuring from the bottom of the connector or flatspot if present, tot he bottom of the manhole and wall thickness of pipe.

CAUTION: When installing pipe stubs for future pipeline, installation of all stubs should be properly restrained to prevent any move-ment by means other than, and in addition to, the resilient connector.

ANY QUESTIONS REGARDING A•LOK INSERTA•LOK INSTALLATION, PLEASE CALL 1-800-822-2565

IMPORTANT:BEVEL AND LUBRICATE PIPEALSO CENTER PIPE BEFOREPUSHING PIPE HOME

LUBRICATE INSIDE OFINSERTA•LOK CONNECTOR

INSTALLATION OF PIPE INTO CONNECTOR

The KEY-LOK™ LIFTING SYSTEMis designed to provide a safe,watertight and economical meansof handling precast concretestructures.

The polypropylene lift pin insert isinstalled during the manufac-tur-ing process and becomes an inte-gral part of the structure with apredetermined thickness of con-crete forming a barrier to preventinfiltration into the structure.

The lift pin and lift bar hardware is designed to provide a safe anddurable means of handling precast concrete structures.

KEY-LOKA•LOK KEY-LOK™

The KEY-LOK™ Lift Pin Insert is molded from a copolymerpolypropylene compound.

The Lift Pin and Lift Bar hardware is designed and made to meetThe Code of Federal Regulations: 29 CFR 1926.704(d) and CFR1926.251(a) (4) for lifting devices. Quality and reliability isassured through testing each device.

The KEY-LOK™ LIFT INSERT is designed with a key slot to preventrotation in the mold and to provide easy form removal in both wet castand dry cast methods of production.

The insert forms a precise cavity to accept the keyed lifting pins. Thisassures minimum movement of the lifting device during handling.

The shape of the insert locks the lifting device into the cavity. As liftingtension is applied, the KEY-LOK™ Lift Pins rotate 90° for removal.

The KEY-LOK™ Lift Pin Insert eliminates the necessity of a cold joint inpatching the lift hole allowing immediate backfilling of the structure,enhancing project quality and safety.

The use of an A-LOK® Manhole Lift Bar assures that the Lift Pins stayperpendicular to the manhole wall while lifting.


LIFTING SYSTEM FOR PRECAST STRUCTURES


The A-LOK® Lift Pin's working load is in observance of FederalRegulation codes 29 CFR 1926. 704 (d) and 29 CFR 1926.251 (a) (4).

MATERIAL

KEY ADVANTAGES

PRODUCT REFERENCES

A.) ASTM-C-478Standard Specification for Precast Reinforced ConcreteManhole Sections.

B.) FEDERAL REGULATION CODES29 CFR 1926.704(c) and (d)29 CFR 1926.251 (a) (4)


Wall Insert WorkingThickness No. Load/Pin(Inches) (lb.)

5 1095 45004-1/2 1096 3400

6 1097 65003-1/2 1098 2000

Listed below are the proof of design testing results:

NOTE: The concrete had a 28 day compressive strength of 4,000PSI. The U-shaped reinforcement in the following illustration, isrequired to obtain the above proof of design.

Certified A-LOK lift bar with Choker chains for lifting cones.

MT


PRODUCTION INSTRUCTIONS

MANHOLE LIFT INSTRUCTIONS

The A•LOK® Lift Bar is designed to provide a safe and economical means of handling pre-cast manholes and other concrete structures. As lifting tension is applied, the lift pins rotate90 degrees in the A•LOK® Insert to a locked position for safe handling.A•LOK® meets OSHA 5:1 safety factor. PLEASE NOTE: Lift Bar, pins and chains should bevertical with manhole when lifting.

WARNING: Serious harm or death may result from safety hazards caused by improper use and installation of this product.Use of this product in applications other than those stated should first be carefully tested prior to general production use. Testing must accurately representintended use, with full consideration to all field conditions and factors of safety. The safe working load of this product should always be observed.PLEASE NOTE: A LIFT BAR SHOWING ANY SIGNS OF DEFORMATION OR WEAKNESS SHOULD BE DISCARDED.

Designed to produce a guaranteed watertight seal between pipe and concrete, the A•LOK X-CEL flexible pipe-to-manhole connector provides maximum performance on the jobsite. Its unique design not only saves valuable project time, but alsoensures longevity andoffers unsurpassed environmental benefits.

A•LOK X-CEL connectors prevent infiltration and ex-filtration into wastewater or stormwater systems, and are installed in the precaststructure in a way that does not require coring or placement after thebase component is cast. This eliminates residual waste from coring, disposal of the slugs or wasted raw material utilization or energy.Once cast-in, the connector becomes an integral component of thestructure wall.

Based on the traditional A•LOK connector, the X-CEL's enhanced features improve performance. Take the patented “water pocket” forexample, which utilizes the untapped pressure of ground water toexert a clamping force around the connector and pipe, allowing theconnector to perform in deeper installations.

Demonstrated in tests higher than 15 psi of hydrostatic water pres-sure, the X-CEL's unique design provides 45 percent more rubbercontact with the pipe, allowing for greater pipe deflection.

X-CELA•LOK X-CEL

Molded or extruded from compounds formulated for wastewaterapplications and engineered to conform to the requirements of section 4.1.1 of ASTM C-923, the standard rubber connector is availablein alternative compounds upon request. Contact an A•LOK representa-tive regarding special applications, such as the presence of hydrocar-bons.

KEY ADVANTAGESThe A•LOK X-CEL offers distinct advantages for engineers, specifiers,precasters and municipalities. An enhanced profile gives the connector45% greater rubber contact with the pipe, thus allowing the pipe to bedeflected in excess of 10 degrees of omnidirectional deflection, all thewhile maintaining a watertight seal. These enhancements allow for more flexibility to compensate for pipe shear due to settlement or ground movement.


INCOMPARABLE PIPE-TO-MANHOLE CONNECTORS FOR SANITARY SYSTEMS


The A•LOK X-CEL guaranteed Connector meets or exceeds all material and test requirements outlined in ASTM C-923: “ResilientConnectors Between Reinforced Concrete Manhole Structures,Pipes and Laterals.”

Molded or extruded from compounds formulated for wastewaterapplications, the standard rubber connector is engineered to confirmwith the requirements of section 4.1.1 of ASTM C-923. Alternativecompounds are available upon special request.

MATERIAL

On larger-diameter pipe, where size prohibits a gasket from beinginstalled in a flat plane, the X-CEL can be configured for casting in acurve with the connector staying perpendicular to the center line of thepipe. Discovered through years of extensive research and development,the configurations cause no loss of compression or deflection.

Functioning on pure compression, the X-CEL allows for fast and easy field installation. After the connector and pipe are cleaned andlubricated, the pipe is simply centered in the connector and inserted.Backfilling can be done immediately, thus enhancing project safety andovercoming the typical problems of water, running sand and other unstable trench conditions.

For Specifiers, the X-CEL connector offers a guaranteed solution to theage-old containment system problem of the best way to connect pipesand concrete structures. Precasters using X-CEL connectors experienceincreased satisfaction due to their ability to offer a complete watertight,guaranteed product, while municipalities that install X-CEL will ultimately spend less on road repair by avoiding the possibility of pot/sinkholes that are often the result of leaking, non-connected, systems.

KEY ADVANTAGES (continued)

PRODUCT REFERENCES

A.) ASTM C-923Resilient Connector Between Reinforced Concrete Manholes Structures, Pipe and Laterals.



MT

DIMENSIONAL DATA

A•LOK X-CEL Cross Sections / Pipe Size OD’s

92 Molded Series4.25” - 7.25”

93 Molded Series8.50” - 13.00”

93 Extruded Series13.25” - 29.00”



Larger Sizes AvailableUpon Special Request

MAX. PIPE SIZE OD’sManhole 135° - 225° 90°Diameter Pipe Angle Pipe Angle

42” 26.5” 22.0”48” 31.5” 25.0”60” 42.0” 32.0”72” 52.5” 38.0”84” 59.5” 44.0”96” 73.5” 50.0”108” 76.0” 56.0”120” 85.0” 62.0”

PRODUCT SPECIFICATIONSA flexible pipe to manhole connector shall be used whenever a pipe penetrates into a precast concrete manhole or structure. The connector shall bethe A•LOK X-CEL CONNECTOR as manufactured by A•LOK PRODUCTS, INC.,Tullytown, PA, or approved equal.


(1) The connector and the structure wall by casting the connector integrally with the structure wall during the manufacturing process in a mannerthat it will not pull out during pipe coupling. The connector shall also be capableof being cast into a round structure by curving the connector in a manner thatallows it to remain centrally located within the structure wall and perpendicularto the pipe. This configuration will result in no loss of seal or deflection of pipeentering a concrete structure.

(2) The seal between the connector and the pipe shall be made by the compres-sion of the connector between the outside circumference of the pipe and the inte-rior hole opening of the structure. The connector shall be the only component toaffect the seal between the pipe and structure.

The connector shall be made from materials that conform to the physical andchemical requirements outlined in Section 4, “Materials and Manufacture” ofASTM C-923 Standard Specification for Resilient Connectors between ReinforcedConcrete Manhole Structures, Pipes, and Laterals, and the overall design will meetor exceed Section 7, “Test Methods and Requirements” of ASTM C-923.








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PERFORMANCE STANDARD (continued)


STEP 1:Confirm that the pipe surface is smooth, cleanand free of foreign materials, chips, gouges andform seams due to manufacturing or handling.Slightly bevel any sharp or blunt edges caused bythe cutting of the pipe.

STEP 2:Lubricate the connector and the entire sectionof the pipe that will be inserted into the connec-tor. The chart below lists A-LOK’s minimumlubrication length “L”.

STEP 3:Center the pipe and connector square to each otherand insert the pipe into the connector using abar or back hoe depending on the size. Oncethe pipe is coupled with the connector, deflect thestructure or pipe to achieve the proper angle.

WARNINGTo ensure the A-LOK X-CEL Connector remainsa flexible watertight connector, it is A-LOKProducts, Inc. strong recommendation that nomortar be placed between the pipe and wall ofthe concrete structure. The use of mortar in thisarea would decrease the effectiveness of the con-nector to compensate for shear caused by settle-ment or ground movement.

NOTE:To find approximate subgrade, measure from theoutside base of the structure to the junction of theconnector and flat spot. Then add the wall thick-ness of the pipe plus 1/4 inch.

CAUTION:When installing pipestubs for future pipelineinstallation, all stubsmust be properlyrestrained to prevent anymovement by meansother than the A-LOK X-CEL Connector.

PIPE SIZE MIN. LUBRICATION LENGTH “L”4” - 15” 12”16” - 18” 18”

21” & Larger 24”



Z•LOK CAST IN BOOT CONNECTORPIPE TO MANHOLE CONNECTOR FOR SANITARY SYSTEMS


The Z•LOK Pipe toManhole Connector isa flexible connectorspecifically engineeredto produce a positivewatertight seal forpipes entering precastconcrete structures andthe structure itself.Its heavier wall isdesigned to provide thehighest performance.The Z•LOKCONNECTOR ismanufactured to meetor exceed therequirements set forthin ASTM C-923 titled“Resilient ConnectorsBetween ReinforcedConcrete ManholeStructures, Pipes, andLaterals”.

Z•LOK PIPE TO MANHOLE CONNECTOR

The Z•LOK CONNECTOR is molded from an EPDM compoundengineered to conform with the requirements of section 4.1.1 ofASTM C-923. Alternative compounds are available for unusualapplications upon special order.

All stainless steel hardware is in compliance with section 4.2,“Mechanical Devices” of ASTM C-923.

KEY ADVANTAGESThe Z•LOK CONNECTOR assures a positive watertight connection andprovides up to 25° of omnidirectional deflection and 1.50" of vertical orhorizontal movement without loss of seal, providing greater flexibility inthe design and installation of pipelines and structures. These designfeatures of the Z•LOK CONNECTOR prevent infiltration due to shearcaused by settlement or ground movement.

The inner rubber O-ring design eliminates rubber wrinkling,compensates for pipe irregularity and wall thickness insuring awatertight seal.

The unique bi-directional design, permits the Z•LOK CONNECTORtake-down clamp to be fastened from either the inside or outside of thestructure. Once fastened, immediate backfilling is possible enhancingproject safety and overcomes the normal problems encountered withwater, running sand and other unstable trench conditions.

When casting the Z•LOK CONNECTOR into the structure, making it anintegral part of the wall, 50% of the opportunity for infiltration iseliminated.

PERFORMANCE STANDARDThe Z•LOK Connector meets or exceeds all material and testrequirements of ASTM C-923: “Resilient Connectors BetweenReinforced Concrete Manhole Structures, Pipes and Laterals”.

See following chart:MATERIAL

PRODUCT REFERENCESA.) ASTM C-923Resilient Connector Between Reinforced Concrete Manholes Structures, Pipe and Laterals.









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MT

A•LOK PRODUCTS INCORPORATED P.O. BOX 1647 • 697 Main Street • Tullytown, PA 19007 • www.a-lok.com • email: [email protected] • 215-547-3366 • 215-547-5260 FAX 8/06

PRODUCT SPECIFICATIONSA flexible pipe to manhole connector shall be used whenever a pipe penetrates into a precast concrete manhole or structure.

The connector shall be the Z•LOK CONNECTOR as manufactured by A•LOKPRODUCTS, INC., Tullytown, PA, or approved equal.


(1) The connector and the structure wall by casting the connector integrally with the structure wall during the manufacturing process in a mannerthat it will not pull out during pipe coupling.

(2) The seal between the connector and the pipe shall be made by compressingthe connector against the outside circumference of the pipe by means of astainless steel take-down band.

The connector shall be made from materials that conform to the physical andchemical requirements outlined in Section 4, “Materials and Manufacture” ofASTM C-923 “Standard Specification for Resilient Connectors BetweenReinforced Concrete Manhole Structures, Pipes, and Laterals”, and the overalldesign will meet or exceed Section 7, “Test Methods and Requirements” of ASTMC-923.



WARNING: To ensure the Z-LOK Connector remains a flexiblewatertight connector, it is A•LOK Products, Inc. strongrecommendation that no mortar be placed between the pipe andwall of the concrete structure. The use of mortar in this area woulddecrease the effectiveness of the connector to compensate forshear caused by settlement or ground movement.

NOTE: The 60 in.-lb. Torque Wrench is available through A•LOKProducts, Inc.

CAUTION: When installing pipe stubs for future pipeline installation,all stubs must be properly restrained to prevent any movement bymeans other than the Z-LOK Connector.

ANY QUESTIONS REGARDING Z-LOK CONNECTOR,PLEASE CALL 1-800-822-2565


Z-LOK PIPE O.D. INCHES CLAMPRING NO. MIN. MAX. NUMBER

C107-1 1.25” 1.75” CL-040C107-2 2.00” 2.50” CL-040C107-3 2.75” 3.75” CL-088C107-4 4.25” 6.25” CL-128C107-6 6.25” 8.25” CL-128F208-8 8.25” 9.10” CL-152C107-8 8.25” 10.25” CL-188

C107-10 10.25” 12.25” CL-188C107-12 12.25” 14.25” CL-248C107-15 14.25” 16.00” CL-EV15-18-LC107-16 16.25” 18.00” CL-EV15-18-LC107-18 18.25" 21.25" CL-EV15-18-L

NOTE:• F208-8 GASKET CAN BE USED ON C107-6 MANDREL• WHEN ORDERING CLAMPS, PIPE OD’S ARE REQUIRED• C107-1 AND C107-2 USE THE SAME MANDREL• C107-16 AND C107-18 USE THE SAME MANDREL• REDI-LOK CLAMP IS REQUIRED FOR C107-15

THROUGH C107-18 GASKETS

STEP 1:Bevel pipe.Clean connector.Clean pipe ofdirt & debris.

OUTSIDE INSTALLATION

STEP 2:Center pipe in connector andpush through.

STEP 3:Attach proper size clampbeside o-ring then centerpipe in connector and VERYIMPORTANT tighten clampwith torque wrench to 60inch pounds.

OUTSIDEOFMANHOLEDO NOTMORTAR

60 IN. LBS.TORQUEWRENCH

INSIDEOFMANHOLEDO NOTMORTARTOP HALFOF PIPELINE

Z-LOK CONNECTOR – INWARD POSITION

INSIDE Z-LOK CONNECTOR INSTALLATION

STEP 4:When installing a Z-LOKconnector in the outside themanhole position pull pipeback out after inserting sothe connector flips outward,then VERY IMPORTANT -center pipe in connectorand tighten the take downclamp to 60 inch poundswith a torque wrench.

BUTYL-LOK


STANDARD SIZE IN STOCK(Custom sizes available)

BUTYL-LOK WRAP

TROWELABLE-PUMPABLEGRADE

ADHESIVE-PRIMER SYSTEMS• Water Emulsion Type (non-flammable)• Solvent Type (flammable)

BUTYL-LOK

CARTRIDGES

BUTYL SEALANT SYSTEMSBUTYL SEALANT SYSTEMS

PREFORMED TAPES

PLASTIC

RUBBER

BUTYL-LOK sealant systems are customed engineered andmanufactured to comply with current standards andspecifications required by the Federal, State and localregulatory agencies for use by the precast concrete industryand its contractors.

BUTYL-LOK sealants are supplied in ready-to-apply forms forall weather installations and conditions. Specific applicationsare:

• SANITARY AND STORM SEWER MANHOLES• PIPE (Round, Oval, Flatbase, Elliptical and Arch types)• BOX CULVERTS• UTILITY VAULTS• BURIAL VAULTS• SEPTIC TANKS AND SEWAGE TREATMENT PLANTS• WET WELLS• PRECAST CONCRETE WALL PANEL SYSTEMS

GENERAL PRODUCT DESCRIPTION

Joint surfaces should be clean and dry. Due to the highadhesive quality of BUTYL-LOK, priming of the joint surfacesis not normally required. However, should wet or unusualapplication conditions exist, it is recommended that eitherBUTYL-LOK Emulsion (non-flam) or Solvent (flammable)Adhesive Primer be coated on the joint surface and allowed todry a minimum of 10 minutes before application of jointsealant.

KEY ADVANTAGES

BUTYL-LOK sealants remain permanently flexible and formpermanent bonds to a wide variety of substrates includingconcrete, metals and plastics. These products are designednot to shrink or oxidize and have excellent resistance toenvironmental temperature extremes, acid and alkalineconditions. Adhesion and cohesion actually improves afterjoint has been formed and placed in service.

SURFACE PREPARATION

PRODUCT REFERENCES

CHEMICAL COMPOSITION

TEST REQUIRE-METHOD MENTS BUTYL-LOK

Butyl Rubber-Hydrocarbon(% by wt.) ASTM D-297 50-70 58%

Inert Mineral Filler(% by wt.) SS-S-210-A 30-50 42.0%

Volatile Matter (% by wt.) ASTM D-6 2.0 Max. 1.0%

BUTYL-LOK meets or exceeds all basic requirements ofFederal Specification *SS-S-21 0-A*AASHTO M-198 and ASTM C-990.

*NOTE: Meets all aspects with exception of flash point and fire point.

BUTYL-LOK bonds instantly to joint surfaces and to itself.Always butt ends of preformed sealant together — neveroverlap. Leave protective release paper on sealant duringapplication and remove only after structure is ready forcoupling. The joint should them be coupled with sufficientpressure for proper joint completion. The resulting annularspace after structure is properly coupled, determines thevolume (cross-section size) of BUTYL-LOK required.

APPLICATION

PHYSICAL PROPERTIES

TEST REQUIRE-METHOD MENTS BUTYL-LOK

Specific Gravity @ 77°F. ASTM D-71 1.15-1.50 1.25-1.35Ductility @ 77°F. ASTM D-113 5.0 Min. 6.0 CMCone Penetration @ 77°F. ASTM D-217 50-100 55-80Flash Point C.O.C. (°F.) ASTM D-92 350 Min. 375Accelerated Aging Maintained

(Mechanical Oven - 99+% Solids4 hours @ 212°F.) (Flexibility not

affected)UV Resistance (Direct FL No Visible

Exposure - 365 days) DamageElongation Initial @ 77°F. 300% Min.

Two Weeks @ 195°F. 300% Min.Two Weeks - Total

Water Immersion 300% Min.Flow Resistance (1" wide

overhead joint exposedto 135°F. for 7 days) No Flow

Storage Life IndefiniteApplication Temp. Range 0 to 120°F.Service Temp. Range -40° to 250°F.

CHEMICAL RESISTANCE

REQUIRE-(Total Immersion 112 Days) MENTS BUTYL-LOKSulfuric Acid 20% No Visible DamageSodium Hydroxide 5% No Visible DamageAmmonium Hydroxide 5% No Visible DamageNitric Acid 1% No Visible DamageFerric Chloride 1% No Visible DamageSoap 0.1% No Visible DamageDetergent

(linear alkyl bensyl sulfonate) 0.1% No Visible Damage

*NOTE: Contains no asbestos fibers or asphaltics.

PRODUCT DIA. CROSS SECTION ROLL ROLLS PER FEET PER CARTON CARTONS PERNO. EQUIVALENT SIZE LENGTH CARTON CARTON WEIGHT PALLET*

FS-3050 1/2" .45" x .45" 21.75' 12 261 35 lbs. 40FS-3075 3/4" .675" x .675" 14.5' 8 116 33 lbs. 40FS-3100 1" .89" x .89" 14.5' 6 87 42 lbs. 40FS-3125 1-1/4" 1.0" x 1.123" 14.5' 5 72.5 55 lbs. 40FS-3150 1-1/2" 1.187" x 1.5" 10.75' 4 43 47 lbs. 40FS-3200 2" 1.875" x 1.675" 7.00' 4 28 52 lbs. 40

DURA-PLATE™ BUTYL-LOK SEALANTMT-320 1/2" x 1-1/2" 14'6" 4 58 28 lbs. 45MT-329-A 5/8" x 3-1/2" 14'6" 2 29 38.2 lbs. 40

FR 500 DURA-PLATE™ LAP SEALANT 1/10 Gallon CartridgesCT-0335 LAP SEALANT-LS600 (WHITE) 1/10 Gallon Cartridges – Packaged 10 tubes/case – 120 cases/pallet*Note: All pallets shrink wrapped – suitable for outside storage.Custom sizes available upon request – Call us with your special requirements.

BK-0069 TROWELABLE – PUMPABLE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Available in 5 gallon pailsR-900 1/10 Gallon CARTRIDGES (BLACK) . . . . . . . . . . . . . . . . . . . . . Packaged 10 tubes/case – 120 cases/palletCN-0189 ADHESIVE-PRIMER: SOLVENT TYPE (flammable) . . . . . . . . . . . . . . . . . . . . . . . 1 Gallon pails – 6 per case

(9% WASH)

BUTYL-LOK SEALANT SYSTEMSPREFORMED TAPES

HORIZONTALINSTALLATION

VERTICAL INSTALLATION

TYPICAL JOINTCONFIGURATIONS

1/64" TO 5/16" TO 9/16" TO1/4** 1/2** 11/16**

12" 1/2" 3/4" 1"15" 1/2" 3/4" 1"18" 1/2" 3/4" 1"21" 1/2" 3/4" 1"24" 3/4" 1" 1-1/4"27" 3/4" 1" 1-1/4"30" 3/4" 1" 1-1/4"33" 3/4" 1" 1-1/4"36" 3/4" 1" 1-1/4"39" 1" 1-1/4" 1-1/4"42" 1" 1-1/4" 1-1/2"45" 1" 1-1/4" 1-1/2"48" 1" 1-1/4" 1-1/2"54" 1-1/4" 1-1/2" 1-3/4"60" 1-1/4" 1-1/2" 1-3/4"66" 1-1/4" 1-1/2" 1-3/4"72" 1-1/4" 1-1/2" 2"78" 1-1/4" 1-1/2" 2"84" 1-1/2" 1-3/4" 2"90" 1-1/2" 1-3/4" 2"96" 1-1/2" 1-3/4" 2"102" 1-1/2" 2" 2"108" 1-1/2" 2" 2"

Bell

Tongue

Tongue Bell

PIPESIZE(ID)

RECOMMENDED SIZES

HORIZONTAL JOINTS

*The annular space of the joint iscalculated by subtracting thetongue O.D. from the bell I.D. anddividing by 2.

1/64" TO 5/16" TO 9/16" TO1/4** 1/2** 11/16**

42" 3/4" 1" 1-1/4"48" 3/4" 1" 1-1/4"54" 1" 1" 1-1/2"60" 1" 1-1/2" 1-1/2"66" 1" 1-1/2" 1-1/2"72" 1" 1-1/2" 1-1/2"84" 1" 1-1/2" 1-3/4"96" 1" 1-1/2" 1-3/4"

ID OFSTRUCTURE

RECOMMENDED SIZES

VERTICAL JOINTS

BUTYL-LOK WRAP

BUTYL-LOK WRAP is an extruded Butyl adhesive tape, designed to provide high strength, watertight sealson properly primed concrete surfaces and joints of any kind. The Butyl compound is soft, tacky andbonded to either a Plastic backing of an E.P.D.M. Rubber backing. Both kinds of tape are wound in rollson a release liner for easy application.

SUGGESTED APPLICATIONS FOR BUTYL-LOK WRAP• Any external concrete joints:

Manhole Joints Arch Pipe JointsRound Pipe Joints Septic JointsBox Culvert Joints Burial Vault JointsElliptical Pipe Joints Grade Ring Joints

• Concrete Bridge Spans• New construction, repair or rehabilitation• Seals vacuum test leaks• Protective pipe wrap in corrosive conditions

ADVANTAGES OF BUTYL-LOK WRAP• Prevents or stops infiltration• Economical sealing solution• Easy application• Excellent initial adhesion and strength• Withstands constant stress at elevated temperatures• Excellent protection against corrosion• Readily available

AVAILABLE IN THE FOLLOWING SIZES:

BUTYL-LOK WRAP is designed to be used with No. 4 primer, and should not be stretchedduring installation.


The Duraplate 100 Lineris a corrosion protectionsystem for concretestructures used inwastewater, stormwaterand light industrialapplications. It is anextremely durable as wellas resilient PVC polymerblend material that isthermoformed into asectional design. Thecompression joints allowfor secure installation ofthe sections during thePrecast process andeliminate the need for welding.

DURA PLATE 100 LINER SYSTEMA•LOK DURA PLATE 100 LINER SYSTEM

The liner and seals are all formed from materials selected for theirchemical resistance properties. The main panel sections are formedfrom a polymer blend, while the vertical panel joints are sealed withan EPDM rubber, and the horizontal structure joints with an approvedpreformed butyl sealant.


The Dura Plate 100 Liner meets or exceeds all material and testrequirements as outlined by the manufacturer.

CORROSION PROTECTION FOR CONCRETE STRUCTURES


MATERIAL

PRODUCT SPECIFICATIONS

A protective liner shall be used whenever a precast concrete manhole orstructure is used in a sanitary or light industrial sewer system in which thepotential for corrosive attack to the concrete substrate exists.

The liner shall be the Dura Plate 100 Liner as manufactured by A-LOK®

Products, Inc., Tullytown, PA or approved equal.

The design of the liner shall provide a corrosion protective barrier permanentlyembedded to the inside wall of the structure. The liner system shall assurethat:

1) The liner shall become an integrally part of the structure wall by castingthe liner with the structure during the manufacturing process. The linershall also be capable of being cast into a round structure by curving theliner in a manner that allows it to remain permanently attached to theinside structure wall.

2) Vertical joints between the liner sections shall be made by the mechanicalcompression of a EPDM rubber strip between the returns of the twopanels with self tapping screws spaced every 3 inches apart.

3) Horizontal joints between structure sections shall be sealed with anapproved butyl strip compressed between the sections in a manner asrecommended by the manufacturer.

4) The liner system shall be composed from materials that are corrosionresistant by nature and conforms to the physical and chemicalrequirements as determined by the manufacturer.

5) The liner shall be sized specifically for the type of structure being usedand shall be installed in accordance with the recommendations of themanufacturer.

The Dura Plate 100 Liner System was designed on a three pointdesign philosophy.

1) The system will provide corrosion protection to the concretesubstrate, by shielding it with a protective barrier of inertmaterial embedded to the inside wall of the structure. Eachpanel features a minimum ½”return on each edge to ensureproper sealing.

2) The design will minimize the freight cost by using a sectionaldesign that will allow the pieces to be nested within each otherwhile being shipped to the precaster.

3) The design will provide easy installation without the need forwelding sections together, but still providing complete corrosionprotection to the structure.

KEY ADVANTAGES

Chemical Resistant:Chemical SolutionSulfuric Acid (H2SO4) 20%Sodium Hydroxide (NaOH) 5%Ammonium Hydroxide (NH3OH) 5%Nitric Acid (HNO3) 1%Ferric Chloride (FeCl3) 1%Soap 0.10%Detergent 0.10%

Physical Properties of Liner Panel:Test ASTM Minimum

Method ValueTensile D-638 6,100 psiElongation D-638 28.5 %Tensile Modulus D-638 325,000 psiFlexural Strength D-790 9,200 psiFlexural Modulus D-790 340,000 psiTensile Impact D-1822 640 in-lbf

MT

PRECAST INSTALLATION INSTRUCTIONS1. Inspect core for sharp or jagged edges that could damage the liner

during the shipping process.2. Place Dura Plate 100 Liner panels level around the core of the form.

Form release agent is not necessary.3. Install the vertical joints by placing the black rubber strip between the

panel returns, making sure that the flap of the strip is fitted over one ofthe returns.

4. Place backing plate on the inside return of panel that the flap fits over.Hold together with spring loaded clamps evenly spaced about 12"apart.

5. Secure the panels together with fasteners placed every 3 inches,making sure that each fastener is tightened to 5 in-lbs.Note: The fasteners must be installed from the side opposite the flap,straight thru the backing plate, parallel to the liner.

6. Repeat for all seams.Note: Caulk can be placed between the form core and liner returns tominimize concrete seepage during production.

7. Install reinforcement into form with any other necessary parts neededfor the structure.

8. Pour concrete around the liner evenly to prevent shifting of the liner.9. Vibrate and compact the concrete in a manner that will protect the liner

and produce a dense, homogenous structure.10. Take precaution to protect the liner from sharp or jagged objects while

stripping from the form.11. Visually inspect the liner after production for any cuts or tears. If repairs

are needed, refer to Dura Plate 100 Liner repair bulletin for properrepair procedures.

12. If steps or ladders are to be installed, drill all holes in liner larger thanthe diameter of the step. Install steps or ladder then caulk area aroundstep and liner with FR500 caulking material (Lap Sealant).

13. Protect all hole opening surfaces with a minimum 1/8 inch coverage ofSewer Guard that overlaps the liner at least a 1½ inches.


ANY QUESTIONS REGARDING A•LOK DURA PLATE 100 LINERSYSTEM INSTALLATION, PLEASE CALL 1-800-822-2565

1. When unloading the structure be careful. Take measures to protect theliner from being damaged by rocks or other debris. Lift carefully, do notdrag.

2. Clean and install butyl strips around the joint design making sure thatthe butyl overlaps both the cement and liner return.

3. Carefully seat each section together making sure enough pressure isapplied to seal the joint.

4. After structure is in place, plug all lift pin inserts and holes with suitablenon-shrink grout.

5. If any damage to the liner occurs at the job site, use Dura Plate 100Liner repair bulletin for proper repair procedures.

WARRANTYA-LOK® Products, Inc. warrants that the product described in this bulletin meets orexceeds all material, quality, and workmanship standards suitable for its intended use.A-LOK® Products, Inc. liability is limited to replacement or repair of defective partsexcluding cost of removal, installation or unauthorized repairs. A-LOK Products, Inc.will not be responsible for incidental or consequential damages or for products whichhave been altered or modified. No representative of the company, or any other person,has the authority to waive, alter or add to this guarantee or to assume for the companyany obligation with the sale or installation of A-LOK Products, Inc. This warranty is inlieu of all other warranties, expressed or implied.

JOB SITE INSTALLATION INSTRUCTIONS

2

5

12

13

DURA PLATE 100 LINERCORROSION RESISTANT SYSTEM

Part 1. The Dura Plate 100 LinerSystem

The objective of this specification is tocover the supply and installation of a vac-uum formed semi-rigid liner for use inwastewater and light industrial concretestructures to effectively shield the interiorof the structure from corrosion.

The design of the liner system shall insurethat it will conform to the contour of thestructure and form a permanent mechani-cal bond to the concrete through use ofpreformed horizontal ribs and dovetails.The liner will be formed in such a mannerthat the joints between the structure sec-tions will be afforded protection throughthe use of a continuous PVC return intothe joint for a minimum of .50 of an inch.Provisions will be made to allow the pipepenetrations to be sealed by applying acementitious corrosion resistant materialto the unlined exposed areas within theopenings.

Part 2. Material

2.1 Liner shall be Dura Plate 100as manufactured by A-LOK® Products,Incorporated, Tullytown, Pennsylvania.

2.2 Liner Composition - The liner,channel joints, H-joints and corner jointsshall be manufactured from an AcrylicPVC Alloy.

All sheet compound will resultin a semi-rigid material suitable for ther-

moforming to the contour of the structureand shall maintain a minimum wall thick-ness of .065 inches.

2.3 Rubber Joint Composition -The fabricated liner panels shall be joinedtogether by a slotted strip of EPDM rub-ber according to the manufacturer’s spec-ification as illustrated in Figure 1A.

Figure 1A - Panel Joint Detail

2.4 Butyl Joint Composition -Sections of lined concrete structures shallbe joined together by an approved butylstrip (A-LOK® Products, Inc. Tullytown,PA. MT-329) designed to produce suffi-cient squeeze-out between PVC returns.

Note: All EPDM and Butyl joint com-pound shall be formulated to meet thechemical resistant properties of Section3.1.1.

Part 3. Physical Properties

3.1 General - All materials shallmeet the physical and chemical resistantproperties specified in the followingappropriate section.

3.1.1 Physical Properties - All semi-rigid liner sheets, joint assembly compo-nents, corner and weld strips shall havethe following properties when tested at 77degrees +/- 5 degrees Fahrenheit.

Chemical Resistant:Chemical SolutionSulfuric Acid (H2SO4) 20%Sodium Hydroxide (NaOH) 5%Ammonium Hydroxide (NH3OH) 5%Nitric Acid (HNO3) 1%Ferric Chloride (FeC13) 1%Soap 0.10%Detergent 0.10%

Physical Properties of Liner Panel:ASTM Minimum

Test Method ValueTensile D-638 6,100 psiElongation D-638 28.5%Tensile Modulus D-638 325,000 psiFlexural Strength D-790 9,200 psiFlexural Modulus D-790 340,000 psiTensile Impact D-1822 640 in-lb

3.1.2 Antifungal and AntibacterialProperties - Dura Plate 100 Liner shall bemade from Acrylic PVC Alloy sheets thatresist bacteriological and fungal develop-ment. Sheet shall not readily provide asource of nutrients for bacteria and fungi.Plasticizers that allow a source of nutri-ents which support microbial growth forbacterial or fungal growth shall not bepermitted.

Sheet shall be subjected to fun-gus resistance testing in accordance withASTM G-21 and bacteria resistance test-ing in accordance with ASTM G-22,Procedure B.

Fungus Resistance Testing,ASTM G-21: Eighteen day cultures ofthe following pure culture fungi were har-vested, washed and their spore countsadjusted to 1,000.000 (±200,000 per ml).

Organism ATCC NumberAspergillus niger 9642 Penicillium pinophilum 11797 Gliocladium virans 9645 Aureobasidum pullulans 15233 Chaetomium globosum 6205

The spore suspensions werecombined and sprayed on the samples andcontrols which were placed on mineralsalts agar and placed in the test chamber.

– 1 –

The samples, along with controls wereincubated for 28 days and examinedweekly.

Sample ObservationsDesignation (Rating*)Thermoplastic 7 14 21 28Sheet: Days Days Days Days#1 0 0 0 0#2 0 0 0 0#3 0 0 0 0 #4 0 0 0 0 Controls:Filter Paper 4 4 4 4 Glass Slides 0 0 0 0 *Rating: 0=no growth. 1=traces,2=light, 3=moderate, 4=heavy growth

Bacteria Resistance Testing,ASTM G-22: Conclusion of FungusResistance Testing: The sheet samplesdid not allow any fungus growth (ratingof 0).

A twenty-four hour culture ofPseudomonas aeruginosa (ATCC 13388)was harvested and washed three times bycentrifugation using sterile distilled water.The bacterial suspension was added tosterile, melted minerals salts agar, mixedand plates poured. A sample of the inocu-lated agar was taken and a plate count todetermine the number of viablepseudomonas present.

Sample ObservationsDesignation (Rating*)Thermoplastic 7 14 21Sheet: Days Days Days#1 0 0 0 #2 0 0 0 #3 0 0 0 #4 0 0 0 Controls:Inoculated Agar 0 0 0 Glass Slides 0 0 0 Plate Count Agar 1 1 1 *Rating: 0=no growth, 1=growth

Conclusion of BacteriaResistance Testing: The sheet samplesdid not allow any bacterial growth (ratingof 0).

Part 4. Details and Dimensions of Standard Liner

4.1 Liner panels shall have a min-imum thickness of .065 inches. A combi-nation of standing ribs and mechanicaldovetails shall be used to secure the linerpanels to the wall of the structure andshall be spaced a maximum of 6.0 inchesapart.

4.2 Liner panels with a combina-tion of standing ribs and dovetails indiameters of 48" through 60" shall be atleast .50 inches high. Panels of 72" diam-eter and above shall be at least .75 incheshigh.

4.3 Liner with locking extensionsshall be able to withstand a test pull of 100pounds per linear inch applied perpendi-cular to the concrete surface for a periodof 60 seconds. No rupture of the lockingextensions or withdrawal from embed-ment shall be acceptable. This test shall bemade at a temperature between 70 and 80degrees Fahrenheit inclusive.

4.4 Liner panels shall be formed tothe correct radius to assure a true diametermatch between joined precast sectionswhen assembled.

4.5 Liner panels shall be formedwith a continuous return into the joint fora minimum of .50 of a inch which shallafford protection between the lined pre-cast sections.

4.6 All radius panels shall be vac-uum tested for pinholes during the mold-ing process and shall withstand a mini-mum of 25 inches of mercury for a periodof 60 seconds.

4.7 Panel sections shall be customformed to a specified height not to exceed6' in overall length. Lengths specifiedshall include a tolerance ratio of +/- .0625per foot.

Part 5. Plant Installation of Liner

5.1 General - Installation of all lin-ing shall be done in accordance with themanufacturer’s recommendations.

5.2 Lining coverage shall not beless than the minimum shown on theapproved shop drawings or constructionplans.

5.3 The liner panels when assem-bled shall form a circular cylinder that fitssnugly against the inner steel core of theform. A removable extruded rubber pro-file or suitable one-sided tape can be usedto seal the liner against the core to preventconcrete fines from washing downbetween the liner and steel core.

5.4 Concrete poured around theliner shall be distributed evenly to preventshifting of the liner.

5.5 Concrete poured against theliner shall be vibrated, or compacted in amanner to protect the liner and produce adense homogenous concrete to securelyanchor the assembly to the exposed sur-faces on the interior of the structure.

5.6 When extracting the steel core,care should be taken to protect the linerfrom damage. Instruments with sharp orjagged edges should not be used to releasethe forms from the liner.

5.7 Visual inspection of the linershall be made after demolding and anycuts or tears shall be repaired by follow-ing the manufacturer’s repair recommen-dations.

5.8 The concrete producer shalltake all necessary measures to preventdamage due to casting, demolding, anddelivery of the lined concrete structure.

Part 6. Field Installation of Lining

6.1 General - Field installation ofall lined precast sections shall be done inaccordance with the recommendations ofthe manufacturer.

6.2 The horizontal joints betweensections of lined concrete structures canbe made by either butyl or a combinationof butyl and rubber joint per the recom-mendation of the concrete manufacturer.(See Fig. 2)

Figure 2 - Butyl Joint

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6.3 Joint surfaces must be clean toensure proper adhesion of the butyl. Anapplication of a butyl based primer willproduce the highest degree of adhesion tothe joint surfaces.

Figure 2A - Spigot Up Joint Detail

6.4 Place specified butyl materialas indicated in Figures 2A and 3A. Buttends of material together. Material shouldnever be overlapped. Butyl material shallbe an approved strip per Section 2.4.

Figure 3A - Bell Up Joint Detail

6.5 Lined sections should be care-fully centered and lowered to completecoupling process. Apply sufficient pres-sure to properly seat joint and achievesqueeze out.

6.6 After structure is in place, careshould be taken to properly plug all liftpin inserts or holes with a suitable non-shrink grout.

6.7 The installing contractor shalltake all necessary measures to preventdamage to the liner due to material han-dling, installation, or equipment or mate-rial used in installing, or used in or takenthrough the structure.

Part 7. Testing and Inspection

7.1 General - This section coversthe in-plant and field inspection and test-ing method of lined concrete sections.

7.2 The liner manufacturer shalltest each panel to withstand a constantvacuum of 25 inches of mercury for aperiod of 60 seconds. Any sections failingto meet this requirement shall be rejected.

7.3 In-plant inspections of panelscast into concrete sections shall be visual-ly inspected for cuts or tears and shall berepaired following the manufacturers rec-ommendations.

Part 8. Liner Appurtenances

8.1 Steps or Ladders

8.1.1 Steps shall be attached byeither casting a preformed polypropyleneinsert to accept a polypropylene drive instep (Fig. 4), or by casting or drilling aprecise hole to accept a polypropylenepress fit step (Fig. 4A), as per the recom-mendations of the step manufacturer.

8.1.2 After installation of either thesteps or ladders, the junction point of thedevice and the liner shall be sealed byapplying an approved butyl caulkingmaterial (A-LOK® Products, Inc.,Tullytown, Pennsylvania, Lap Sealant).

Figure 4 - Casting in PolypropyleneStep Insert

Figure 4A - Drilled Hole Detail forSteps or Ladders

Figure 5

8.2 Hole Liners

8.2.1 Pipe penetrations through thelined wall shall be afforded protection byapplying .125 inch trowelable, chemicaland corrosion resistant epoxy mortar tothe unlined exposed areas within theopenings and shall overlap the liner wall aminimum of 1.50 inches as illustrated inFigure 5A.

Figure 5A - Hole Liner Detail

8.3 Grade Work Protection

8.3.1 Corrosion protection betweenthe lined concrete structure and the castiron frame and cover shall be obtainedthrough the use of a telescoping LinerSystem (A-LOK® Products, Inc.,

Epoxy LinerProtection OfHole Opening.

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Tullytown, Pennsylvania, Water-LOKConnector) illustrated in Figure 6A below.

Figure 6A - Water-LOK Componentsand Duraplate Slab Top Liner

8.3.2 Corrosion protectionshall be afforded for aluminum entryframes and doors by fabricating a semi-rigid riser to match the inside dimensionsof the access frame.

Figure 7A - Duraplate Slab TopWith Opening

Part 9. Warranty

A-LOK® Products, Incorporatedwarrants that the product described in thisbulletin meets that material, quality, andworkmanship conformable to the recom-mended use.

A-LOK® Products, Incorporated lia-bility is limited to replacement or repair ofdefective parts, excluding cost ofremoval, installation or unauthorizedrepairs. A-LOK® Products will not beresponsible for incidental or consequen-tial damages or for products which havebeen altered or modified. No representa-tive of the company, or any other person,has the authority to waive, alter or add tothis guarantee or to assume for the compa-ny any obligation or liability in connec-tion with the sale or installation of A-LOK® Products, Inc. products. This war-ranty is in lieu of all other warranties,express or implied.

A-LOK® Products, Inc. StandardTerms and Conditions of Sale apply topurchase of this product.

All information is subjected tochange without notice.

Part 10. Specifications of Manhole Coatings and Linings

Interior Lining

(1) The concrete structure shall have aliner that is integrally cast with theprecast section, at the time of manu-facture.

(2) The liner shall be manufacturedfrom an acrylic modified PVC alloy.

(3) The liner shall be thermo-vacuumformed to create a semi-rigid liner.

(4) The liner shall conform to the interi-or diameter of the structure.

(5) The liner shall be formed with dove-tail ribs so that it is securelyanchored to the concrete structure.

(6) The liner shall be formed withreturns into the bell and spigot jointsto allow for butyl sealant to beplaced and to eliminate the need forany field welding of the joint.

(7) The liner shall be light in color toreflect light.

(8) The liner shall have both antifungaland antibacterial properties that willnot readily provide a source of nutri-ents for bacteria or fungi.

(9) The liner shall be a minimum of.065" thick.

(10) The liner panels shall be joinedtogether by an EPDM slotted rubberstrip.

(11) All materials shall meet the physicaland chemical properties specified inthe appropriate ASTM specification.

(12) The liner shall be Dura Plate 100 asmanufactured by A-LOK® Products,Incorporated. Tullytown, PA, orapproved equal.

THE COMPANY WITH CONNECTIONS®

P.O. Box 1647 • 697 Main Street • Tullytown, PA 19007800-822-2565 • 215-547-3366 • 215-547-5260 FAXwww.a-lok.com • email: [email protected]

Copyright 2007 A-LOK® Products, Incorporated

US Patents 4,751,799 and 5,081,802Canadian Patents 1,285,501 and 2,030,017Other Patents Pending

Dura Plate LinerSlab Top

– 4 –

MANHOLES PART I: GENERAL

A. Precast Concrete Manholes

1) Manholes shall be made of precast concrete sections of which the top section shall be eccentric or flat slab top. The bottom section shall be a precast concrete manhole base.

2) Poured in place bases will not be acceptable. 3) All precast manhole sections shall be manufactured in

accordance with and meet the requirements of specification ASTM C-478, latest revision.

4) All precast manhole sections shall be manufactured by the wet cast method.

5) The minimum compressive strength of the concrete for all sections shall be 4000 psi (27 MPa). The maximum allowable absorption of the concrete shall not exceed 9 percent of the dry weight. Tests, when required, shall be in accordance with ASTM C-497, “Determining Physical Properties of Concrete Pipe or Tile”, latest revision.

6) Steel reinforcement for all manhole diameters shall be in accordance with ASTM C-478, latest revision.

PART II: PRODUCTS

A. Precast Concrete Manholes

1) Standard Manhole a) The manholes shall be constructed of precast reinforced

concrete manhole sections. The sections shall be a minimum of four feet (1219 mm) in diameter for pipe sizes up to and including 20 inches (508 mm) internal diameter (for pipe sizes with an internal diameter 24 inches (610 mm) and greater, see Plans).

b) The sections shall conform to the requirements of “Specification for Precast Reinforced Concrete Manhole Sections” (ASTM C-478, latest revision). Joints shall be sealed with a preformed plastic gasket that meets all the requirements of ASTM C-990, “Standard Specification for Joints for Concrete Pipe, Manholes, and Precast Box Sections”, Butyl-Lok as manufactured by A-Lok Products Corporation, Trenton, New Jersey or D-Lok rubber gasket as specified to meet the requirements of ASTM specification C-443, as supplied by Atlantic Concrete Products Company, Tullytown, PA or an approved equal.

c) Manhole Bases

1) Manhole bases shall be precast reinforced concrete. Poured in place bases will not be acceptable.

2) The bases shall be monolithically cast and shall

Manholes p.2

consist of a manhole bottom and a wall which shall extend a minimum of 10 inches (254 mm) above the top of the highest influent sewer. The top of the base section shall be carefully formed to receive the tongue of the barrel section. There shall be a minimum distance of 3 inches (76 mm) between the invert of the lowest effluent sewer and floor of the precast base to provide for the construction of a formed invert and bench wall within the manhole. No more than two lift inserts or holes shall be cast in the bases. a) All precast manhole bases shall have pipe to

manhole flexible seals as manufactured by A-LOK Products Corporation Tullytown, PA., “A-LOK full compression seals” or an approved equal. 1) Pipe seals up to and including 20 inches (508

mm) in size shall be cast into 48” (1219 mm) diameter manhole bases.

2) 21 inch (533 mm) through 30 inch (762 mm) pipe seals shall be cast into 60 inch (1524 mm) diameter manhole bases.



5) 60 inch (1524 mm) pipe seals shall be cast into 120 inch (3048 mm) diameter manhole bases.

6) Flexible pipe to manhole seals shall meet all the test and performance requirements of ASTM specification C-923, “Standard Specification for Resilient Connectors Between Reinforced Concrete Manhole Structures, Pipes and Laterals”.

7) Installation of pipe to manhole flexible seals shall be made in accordance with the manufacturers suggested specifications.

b) Manholes 4 feet (1219 mm) in diameter shall have a bottom at least 6 inches (152 mm) thick and a wall at least 5 inches (127 mm) thick.

c) Manholes 5 feet (1524 mm) in diameter shall have a bottom at least 8 inches (203 mm) thick and a wall at least 6 inches (152 mm) thick.

d) Manholes 6 feet (1829 mm) in diameter shall have a bottom at least 8 inches (203 mm) thick and a wall 7 inches (178 mm) thick.

e) Manholes 7 feet (2134 mm) in diameter shall have a bottom at least 12 inches (305 mm) thick and a wall at least 8 inches (203 mm) thick.

f) Manholes 8 feet (2438 mm) in diameter shall have a bottom at least 12 inches (305 mm) thick and a wall at least 9 inches (229 mm) thick.

Manholes p.3

g) Manholes 10 feet (3048 mm) in diameter shall have a bottom at least 12 inches (305 mm) thick and a wall 10 inches (254 mm) thick.

h) Manholes 12 feet (3658 mm) in diameter shall have a bottom at least 12 inches (305 mm) thick and a wall 12 inches (305 mm) thick.

d) Risers and Top Section 1) The top of base walls, the ends of reinforced

concrete risers and the bottom ends of precast tops shall be so formed that when risers and tops are assembled with the base, they will make a continuous manhole. Joints shall be of such design as will permit effective joining and placement without irregularities in the interior wall surface of the manhole.

2) Manhole barrels shall consist of riser and top section with a minimum wall thickness of 5 inches (127 mm). The top section shall be an eccentric conical section with thickened upper walls with the smallest inside diameter equal to 24 inches (610 mm), to receive the manhole frame and cover. No more than 2 lift inserts shall be cast in each barrel or top section.

B. Manhole Steps

1) Manhole steps shall be of extruded 6061-T6 aluminum or

Polypropylene step #PS4B as manufactured by M.A. Industries, Peachtree City, Georgia or approved equal.

2) Manhole steps shall be cast into the walls of base, risers and conical top sections, and shall be aligned vertically and spaced so as to be on equal centers in the assembled manhole at a maximum distance apart of 12 inches (305 mm). Steps shall be located a minimum of 6 inches (152 mm) from the ends of base, riser, and top sections, and shall be securely embedded in manhole sections by mortar or cast in place polypropylene inserts.

3) Manhole step dimensions shall meet the requirements of OSHA Standard 1910.27 for fixed ladders.

C. Manhole Frames and Covers

1) Casting shall be tough gray iron, free from cracks, holes,

swells, and cold shuts. All manhole casting shall be made accurately to the pattern and to the dimensions shown on Plans, and shall be planed where marked, or where otherwise necessary to secure perfectly flat and true surfaces. All lids which “rock” and do not lie solid after construction is finished will be condemned and must be replaced by perfect lids.

2) Anchor Bolts a) Anchor Bolts for bolting manhole frame to precast or

brick manholes shall be ¾” (19 mm) diameter galvanized

Manholes p.4

all thread steel rods with 5 inch (127 mm) hook for embedment in the manhole top and a minimum 2 inch (51 mm) projection through the bars of the frame.

b) Two Bolt Slots or inserts shall be cast into the manhole top, positioned at 180 degrees at the time of manufacture.

PART III: EXECUTION

A. Precast Concrete Bases

1) All precast concrete bases shall be installed on a layer of crushed stone which shall have a minimum depth of 6 inches (152 mm). The crushed stone shall conform to the quality and grading requirements specified in Section 703.3 of the Pennsylvania Department of Transportation Specifications Form 408 for No. 1B - Type C crushed stone coarse aggregate.

2) All pipe openings shall have pipe to manhole flexible seals as previously mentioned.

3) In constructing “Drop Manholes”, the Contractor shall use one of the following methods: a) Encase and support the riser and incoming pipe with

concrete down to undisturbed earth as shown on the Detail Sheet. The cost of this concrete shall be included in the price of the drop manhole. Encasing the riser with brick will not be acceptable. Care shall be taken to have all pipes laid to correct lines and grades before concreting is undertaken.

b) Purchase precast base with a 90 degree bend precasted into the base section and protect the vertical pipe with precast Drop Collars.

atlantic concrete products, inc. · 2020. 2. 16. · atlantic concrete products, inc. po box 129,...

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