1-75 50932-97

1995 Metric Houston District

SPECIAL SPECIFICATION5093

Water Mains

1. Description. 5

2. Materials. 5

(1) General. 5

(2) Steel Pipe and Fittings. 5(a) Steel Carrier Pipe. 6(b) Steel Casing Pipe. 7(c) Steel Pipe Fittings. 8(d) Steel Pipe Flanges. 8(e) Steel Pipe Protective Coatings. 9

(3) Ductile-Iron Pipe and Fittings. 12(a) Ductile-Iron Pipe, 100 Through 1200 Millimeters. 12(b) Fittings for Ductile-Iron Pipe. 13

(4) Cast-Iron Pipe and Fittings. 13(a) Cast-Iron Pipe, 100 Through 600 Millimeters. 13(b) Cast-Iron Fittings. 13

(5) Polyvinyl Chloride Pipe and Fittings. 14(a) Polyvinyl Chloride (PVC) Pipe, 50 Through 400 Millimeters. 14(b) Fittings for Polyvinyl Chloride Pipe, 50 Millimeter. 14(c) Polyvinyl Chloride Pipe, 100 Through 400 Millimeters. 14(d) Bends and Fittings for PVC Pipe, 100 Through 400 Millimeters. 15(e) Nonmetallic Pipe Detection. 15

(6) Prestressed Concrete Cylinder Pipe and Fittings. 15(a) General 15(b) Prestressed Concrete Cylinder Pipe Design. 15(c) Prestressing Wire. 16(d) Prestressed Concrete Cylinder Pipe. 18(e) Fittings and Specials for Prestressed Concrete Cylinder Pipe. 19(f) Grout for Joints. 19(g) Manufacturer's Quality Control. 19

(7) Joint Bonding and Electrical Insulation. 20(a) Insulating Gasket: 20(b) Sleeves and Washers: 21

(8) Copper Tubing for Copper Service Lines and Small Mains. 21

(9) Brass Fittings for Underground Services Lines and Small Mains. 21(a) General. 21(b) Corporation Stops. 22(c) Curb Stops. 22(d) Service Saddles. 22(e) Angle Stops. 23(f) Fittings. 23

2-75 50932-97

(10) Gate Valves, Tapping Valves and Tapping Sleeves. 23(a) Gate Valves. 23(b) Tapping Valves. 26(c) Tapping Sleeves. 26(d) Air Release and Vacuum Relief Valve. 27(e) External Coating Above Ground Valves. 28

(11) Butterfly Valves. 28

(12) Valve Boxes. 29

(13) Fire Hydrants. 30(a) General. 30(b) Hydrant Barrel. 30(c) Shut-off Valve and Inlet Shoe. 31(d) Valve Stem. 32(e) Gaskets and Seals. 32(f) Painting. 32(g) Performance Standards 34(h) Hydrant Lead. 35

(14) Polyethylene Film Wrap. 55(a) General. 35(b) Film. 35(c) Polyethylene Tape. 36

(15) Bedding Material. 36(a) Bank Run Sand. 36(b) Concrete Sand. 36(c) Pea Gravel. 37(d) Gem Sand. 37

(16) Backfill Material. 37(a) Cement Stabilized Sand. 37(b) Earth or Native Soil. 38(c) Bank Run Sand. 38

(17) Concrete. 38

(18) Grout for Prestressed Concrete Cylinder Pipe Joints. 38(a) General. 38(b) Cement Grout Mixture. 38(c) Nonshrink Grout. 38

(19) Water Meters, Meter Vaults and Meter Boxes. 39(a) Water Meters. 39(b) Meter Vault. 40(c) Meter Box. 41

(20) Affidavit of Compliance. 43

(21) Pressure Reducing Station. 43

3. Construction Methods. 43

(1) Excavation. 43(a) Trenches. 43(b) Existing Streets. 45

(2) Jacking, Tunneling or Augering. 45(a) General. 45(b) Jacking of Steel Casing. 46(c) Tunneling. 46

3-75 50932-97

(d) Augering. 46(e) Bedding for Trenches, Jacking, Tunneling, Boring or Augering Pits. 47

(3) Handling of Pipe and Accessories. 48

(4) Pipe Cutting. 49

(5) Defective or Damaged Material. 49

(6) Cleaning of Pipe and Accessories. 49

(7) Laying of Pipe. 50

(8) Joining of Pipe and Accessories. 51(a) Cast-Iron Pipe, Ductile-Iron Pipe, Valves, Hydrants and Fittings. 51(b) Polyvinyl Chloride Pipe and Accessories. 52(c) Welded Joints for Steel Pipe. 52(d) Flanged Joints for Steel Pipe. 53(e) Rubber Gasketed Bell-and-Spigot Joints For Use On Prestressed Concrete Cylinder Pipe. 54(f) Welded Joints For Use On Prestressed Concrete Cylinder Pipe. 54(g) Flanged Joints For Use On Ductile-Iron Pipe and Prestressed Concrete Cylinder Pipe. 54(h) Joint Grouting For Use On Prestressed Concrete Cylinder Pipe. 54

(9) Closures and Field Modifications of Prestressed Concrete Cylinder Pipe. 56

(10) Thrust Restraint. 56

(11) Electrical Continuity Bonds. 56

(12) Backfilling. 57(a) General. 57(b) Pipe Backfill for Water Mains. 57

(13) Valves and Fire Hydrants. 58

(14) Tapping Sleeves and Valves. 58(a) General. 58(b) Installation. 59

(15) Boxes for Valves. 59

(16) Wet Connections. 60

(17) Polyethylene Film Wrap. 60(a) Tubular Type Wrap. 61(b) Sheet Type Wrap. 62(c) Auger Section Installation. 62

(18) Sterilization of Mains and Testing for Leakage. 62(a) Sterilization of Mains. 62(b) Testing for Leakage. 63

(19) Mains - Use of Completed Sections. 64

(20) Mains - Lowering. 64

(21) Copper Service Line Construction. 64(a) Installing Service Lines. 64(b) Corporation Stop Installation. 65(c) Curb Stop Installation. 66(d) Sequence of Work. 66

(22) Cutting and Plugging of Water Mains. 66

(23) Service Lines of Public Utilities. 67

(24) Relocation of Meter Vaults. 67(a) Precast Concrete Vault. 67

4-75 50932-97

(b) Cast-in-Place Concrete Vault. 67(c) Frame and Cover. 67(d) Inspections. 67

(25) Adjustment of Existing Surface Structures. 68(a) Valve Boxes. 68(b) Meter Boxes. 68(c) Meter Vaults. 68

(26) Relocation of Water Meters and Boxes. 68

(27) Installation of Split Casing. 69

(28) Modifications for Cathodic Protection. 69(a) General. 69(b) Bonded Joints. 69

(29) Removing and Salvaging Fire Hydrants and Water Meters. 70

(30) Installation of the Nonmetallic Pipe Detection System. 70

(31) Removing Water Main and/or Removing Water Main with Casing. 70

4. Measurement. 70

5. Payment. 71

5-75 50932-97

1995 Metric Houston District

Special SpecificationItem 5093

Water Mains

1. Description. This Item shall consist of furnishing all labor, materials and equipmentnecessary to provide a complete water main system in accordance with the plans andspecifications, and in compliance with the Department's Utility Accommodation Policy(Title 43, T.A.C., Sections 21.31-21.55). The water mains shall be of the sizes, materialsand dimensions shown on the plans and shall include all pipe, all joints and connections tonew and existing pipes, all casing, valves, fittings, fire hydrants, meters, blocking, etc., asmay be required to complete the work.

This Item shall also govern for the materials and equipment to be furnished and for themethods to be followed for encasing existing water lines with split steel encasement pipe, bythe open cut method.

The abbreviations AWWA, ASA, ANSI, ASTM and NACE as used in this specification,shall refer to the following organizations or technical societies.

AWWA - American Water Works Association

ASA - American Standards Association

ASTM - American Society for Testing and Materials

ANSI - American National Standards Institute

NACE - National Association of Corrosion Engineers

Where reference is made to specifications of the above organizations, it shall be construed tomean the latest standard or tentative standard in effect on the date of the proposal.

2. Materials.

(1) General. All pipe 150 millimeters in diameter and larger shall be acceptable, withoutpenalty, to the Texas Fire Insurance Commission for use in water works distributionsystems.

All materials used in this project shall be new and unused unless otherwise specified onthe plans or in the proposal.

(2) Steel Pipe and Fittings.

(a) Steel Carrier Pipe. All steel pipe, 100 through 600 millimeters which is intendedfor use as carrier pipe in the distribution system shall conform to the requirementsof AWWA Standard C200. All pipe and fittings must have manufacturer'scertifications to ensure that they have been hydrostatically tested at the factory inaccordance with AWWA C200, section 3.4. Pipe steel shall meet the requirements

6-75 50932-97

of ASTM A36, ASTM A570 Grade 36, ASTM A53 Grade B, ASTM A135 GradeB, or ASTM A139 Grade B as a minimum. Pipe shall also be subject to therequirements of Underwriters Laboratories, Inc. Specification for "Steel Pipelinesfor Underground Water Service".

Pipe and fittings shall be designed to withstand the most critical simultaneousapplication of external loads and internal pressures. The design shall be based onthe minimum of AASHTO HS-20 loading, AREA E-80 loads and depths of bury asindicated on the plans. The design shall provide for the most critical groundwaterlevel condition. The pipe design conditions are as follows:

1) Working pressure = 517 kilopascals.

2) Hydrostatic field test pressure = 862 kilopascals.

Pipe design (600 millimeters and larger) shall conform to AWWA M11 withfollowing conditions:

1) Design stress due to working pressure: No more than 50 percent ofminimum yield, 103 megapascals maximum stress for mortar-coated pipe.

2) Design stress due to hydraulic test pressure: No more than 75 percent ofminimum yield, 155 megapascals maximum stress for mortar-coated pipe.

3) Design stress due to maximum hydraulic surge pressure: No more than 75percent of minimum yield, 155 megapascals maximum stress for mortar-coated pipe.

4) Modulus of soil reaction (E'), 10.3 megapascals.

5) Unit weight of fill (w) > 1922 kilograms per cubic meter.

6) Deflection lag factor (D1) = 1.2.

7) Bedding constant (K) = 0.1.

8) Fully saturated soil conditions: hw = h = depth of cover above top of pipe.

9) Maximum deflection from specified diameter.

A. Two percent for mortar coatings.

B. Three percent for flexible coatings and shop-applied mortar lining.

All pipe designs shall be done by a licensed Engineer. The calculations shall besigned, sealed and dated by the licensed Engineer. Prior to manufacturing, thesecalculations shall be submitted to the Engineer for approval.

Pipe shall be supplied in double random lengths unless otherwise specified on theplans. The ends of the pipe shall be beveled for field butt welding.

Minimum allowable steel wall thicknesses shall be in accordance with thefollowing tables for HS-20 live loads and depths of bury of up to 4.88 meters.

7-75 50932-97

CARRIER PIPE

NominalPipeSize,

Millimeters

Corresp.Casing Pipe

Size,Millimeters

MinimumOutside

Diameter,Millimeters

WallThickness,Millimeters

Approx. Wt.Per MeterUncoated,Kilograms

100 200 115 6.35 16.89150 250 167 7.11 28.23200 300 217 8.18 42.49250 350 270 9.27 60.24300 400 320 9.53 73.75400 500 400 9.53 93.13500 600 500 9.53 116.97600 750 600 9.53 140.81

For water mains less than 900 millimeters in diameter, casing insulators shall beused between the water main and casing unless otherwise noted on the plans. Forwater mains 100 through 350 millimeters, 200 millimeter wide casing insulatorsshall be used. For water mains 400 through 900 millimeters, 300 millimeter wideinsulators shall be used. For welded steel pipe 300 millimeters and smaller, use ofPipeline Seal and Insulator Model PE or approved equal shall be required. Forother pipe materials up to 300 millimeters, use Pipeline Seal and Insulator ModelC8G-2 or approved equal shall be required. For all water mains larger than 300millimeters use of Pipeline Seal and Insulator Model C12G-2 or approved equalshall be required.

Casing end seals (Pipeline Seal and Insulator Model C or approved equal) shall beused for water mains less than 900 millimeters in diameter.

NOTE: It is the design Engineer's responsibility to review the design for conditionsmore extreme than those indicated by this specification and design accordingly. Inno case, however, shall thickness of the pipe wall be less than that defined in theabove table.

(b) Steel Casing Pipe. All pipe intended for use as casing pipe shall be manufacturedin accordance with Section 2.(2)(a), "Steel Carrier Pipe", of this specificationexcept that the minimum allowable steel wall thicknesses shall conform to thoseshown in the following table for HS-20 live loads and depths of bury of up to 4.88meters.

8-75 50932-97

CASING PIPE

Casing PipeSize,

Millimeters

OutsideDiameter,

Millimeters

MinimumWall

Thickness,Millimeters

Approx. Wt.Per MeterUncoated,Kilograms

200 217 5.56 29.23250 270 5.56 36.61300 320 5.56 43.57350 350 5.56 47.62400 400 5.56 54.85500 500 6.35 78.47600 600 6.35 94.36750 750 6.65 118.20

NOTE: It is the design Engineer's responsibility to review the design for conditionsmore extreme than those indicated by this specification and design accordingly. Inno case, however, shall thickness of the pipe wall be less than that defined in theabove table.

The steel casing sections for split casing shall be a maximum of 6 meters in length.Each section shall be split in half sections. The ends and split sections shall bebeveled for field butt welding.

Steel casing pipe will not be required to carry the label of the UnderwritersLaboratories, Inc.

(c) Steel Pipe Fittings. All steel pipe fittings, 100 through 600 millimeters, shall befactory forged fittings unless otherwise shown on the plans. The wall thicknessshall be equal to or greater than the pipe to which the fitting is to be welded. Theends of the fitting shall be beveled for field butt welding.

All bends shall be long radius fittings unless otherwise shown on the plans.

(d) Steel Pipe Flanges. Steel pipe flanges, where called for on the plans, shallconform to AWWA Standard C207 for Class D Flanges (same diameter anddrilling as Class 125 cast-iron flanges ASA B16.1).

All cast-iron to steel pipe connections shall be made with one (1) cast-iron bellflange and one (1) steel slip-on flange and shall be electrically isolated. The use ofinsulating gaskets, plastic bolt sleeves and washers of insulating gasket materialbacked with zinc plated or hot-dip galvanized washers, or, epoxy coated bolts, nutsand washers used with an insulating gasket are approved for this purpose.

For inline flange joints 300 millimeters in diameter and greater and butterfly valveflanges, Pyrox LineBacker Type E phenolic gaskets as manufactured by PipelineSeal and Insulator Inc., or approved equal shall be used.

Full-face gaskets for all other flanged joints not listed above shall be used. Cloth-inserted rubber gasket material, 3 millimeters thick in accordance with AWWAC207 shall be provided. Gaskets shall be factory cut to proper dimensions.

9-75 50932-97

Maintain electrically isolated flanged joints between steel and cast-iron by usingepoxy coated bolts, nuts, washers and insulating type gaskets unless otherwiseapproved by the Engineer.

(e) Steel Pipe Protective Coatings.

(i) General. All protective coatings shall be shop applied except for field repairsand coatings of field welded joints. The Engineer may provide for witness ofinspection and testing of shop applied coatings, however, such witness shallnot relieve the Contractor of the responsibility to furnish material, performwork and provide quality control in accordance with the applicable AWWAStandard and/or the requirements of these specifications.

The substrate surface profile and minimum and maximum individual and totaldry film thickness (DFT) indicated herein shall apply. No requirement of thisspecification shall cancel or supersede the specific written directions andrecommendations of the specific coating manufacturer so as to jeopardize theintegrity of the applied system. Dry film thickness shall be measured inaccordance with SSPC PA2.

All shop coating and field repairs shall be field tested by the Contractor forholidays, pinholes or discontinuities at voltage levels required by theapplicable AWWA Standard and in accordance with the applicable NACEprocedure, i.e., PRO 188, RPO 274, TMD 384, etc. The test procedure,including voltage levels to be used, shall be submitted to the City prior totesting.

All holidays shall be repaired in accordance with the applicable AWWAStandard. Documentation by a NACE certified inspector of compliance withthe tests required herein shall be provided by the Contractor.

Handling, storage, and field procedures for shop coated pipe shall be inaccordance with the applicable AWWA Standards. All pipe ends shall beadequately sealed and protected from damage during handling and storage, andsuch protection shall not be removed until immediately prior to installation.Pipe shall not be lifted using caliper clamps or hooks at ends of pipe. Anydamage to the pipe or the protective coating from any cause during theinstallation of the pipe and before final acceptance by the owner shall berepaired as directed by the Engineer and in accordance with the applicablestandards.

The interior of the pipe and fittings shall be kept clean of all foreign matterbefore installation and until the work has been accepted. Joint contact surfacesshall be kept clean until jointing is complete.

The Contractor shall furnish an affidavit of compliance that all materials andwork furnished comply with the requirements of the applicable AWWAStandard and these specifications.

10-75 50932-97

(ii) Internal Lining for Steel. All material used for internal coating of steelcarrier pipe must be NSF61 listed as suitable for contact with potable water asrequired by Chapter 290, Rules & Regulations for Public Systems, TexasNatural Resource Conservation Commission (TNRCC).

All steel carrier pipe and fittings above and below ground, shall be internallylined with either of the following systems unless otherwise shown on the plans.

Liquid Epoxy shall meet the requirements of AWWA C-210, "Liquid EpoxyCoating System for the Interior and Exterior of Steel Water Pipelines," exceptas modified herein. The Liquid Epoxy system shall consist of three coats ofpolyamide epoxy (no coal tar material) as follows:

Prime Coat - two part, chemically cured,pigmented, polyamide epoxy;100-150 micrometers dry filmthickness (DFT).

Intermediate Coat - two part polyamide epoxy;100-150 micrometers DFT.

Finish Coat - two part polyamide epoxy,100-150 micrometers DFT.

The total system shall have a minimum DFT of 300 micrometers and amaximum DFT of 450 micrometers. Each coat shall be in contrasting colors,with the prime and intermediate coat being buff and the finish coat beingwhite. All material shall be supplied by the same manufacturer. Coal-tarepoxy material is not permitted. Surfaces to be coated shall be abrasive blastcleaned to a near white finish in accordance with SSPC-SP10 (NACE 2) toestablish an average anchor profile of 50 to 75 micrometers, with no individualreading greater than 100 micrometers or less than 38 micrometers. Prior toapplying, the prepared and cleaned surface is to be inspected for evidence ofnon-visible contaminants such as soluble salts and/or chlorides in accordancewith NACE Technical Committee Report "Surface Preparation ofContaminated Steel Surfaces," NACE Publication 6G 186. The surface shall berecleaned as necessary until free of such contaminants.

Fusion Bonded Epoxy shall be in accordance with AWWA C- 213, "Fusion-Bonded Epoxy Coating for the Interior and Exterior of Steel Water Pipelines".

(iii) External Coating.

1) Above Ground. All above ground steel piping and fittings shall beexternally coated with a three (3) coat epoxy/epoxy/polyurethane systemin accordance with AWWA C-218, "Coating the Exterior of AbovegroundSteel Water Pipelines and Fittings", Section 2.5, Coating System No. 4-91,except as modified herein.

11-75 50932-97

Prime Coat - two (2) component, pigmented,catalyzed polyamide epoxy primer;DFT of 75-100 micrometers.

Intermediate Coat - two (2) component, catalyzedpolyamide epoxy; DFT of 100-150micrometers.

Finish Coat - two (2) component aliphaticpolyurethane; DFT of 75-100micrometers.

The total system shall have a minimum DFT of 250 micrometers and amaximum DFT of 350 micrometers. Each coat shall be in contrastingcolors, with the prime coat being buff and the finish coat being blue or asspecified by the Engineer. All material shall be supplied by the samemanufacturer. Surfaces to be coated shall be abrasive blast cleaned to anear white finish in accordance with SSPC-SP10(NACE 2) to establish anaverage anchor profile of 50-75 micrometers, with no individual readinggreater than 100 micrometers or less than 38 micrometers. Prior tocoating, the prepared and cleaned surface is to be inspected for evidenceof non-visible contaminants such as soluble salts and/or chlorides inaccordance with NACE Technical committee Report "Surface Preparationof Contaminated Steel Surfaces," NACE Publication 6G 186. The surfaceshall be recleaned as necessary until it is free of such contaminants.

2) Buried Steel Pipe. Buried steel pipe and fittings (except tunneled, cased,or augered holes) shall be coated with either of the following systems:

a) Coal tar enamel and tape, hot applied, in accordance with AWWAC203 "Coal-Tar Protective Coatings and Linings for Steel WaterPipe-Enamel and Tape - Hot Applied."

The system for pipe shall be in accordance with Section 2 of C203and consist of a coat of primer, followed by a hot coat of coal-tarenamel onto which shall be applied a single layer of any of the four(4) outerwraps designated by C203, except that coal-tar saturatedmineral felt is to be used instead of coal-tar saturated asbestos felt.The coating is to be finished with a single wrap of kraft paper. Coal-tar tapes, hot applied, shall be used for special sections, connections,and fitting in accordance with Section 3 of C203.

b) Cold applied tape coating system applied as a three-layer systemconsisting of (1) a prime layer, (2) an inner-layer tape for corrosionprotection, and (3) an outer-layer tape for mechanical protection, inaccordance with the requirements of AWWA C214, "Tape CoatingSystems for the Exterior of Steel Water Pipelines."

Special sections, connections, and fittings shall be coated inaccordance with AWWA C-209, "Cold- Applied Tape Coatings forthe Exterior of Special Sections, Connections, and Fittings for SteelWater Pipelines."

12-75 50932-97

3) Steel Pipe in Tunneled, Cased, or Augered Holes.

a) Steel pipe in tunneled or cased holes, with annular grout, shall beprimed with 75 to 100 micrometers of a two (2) part chemically curedrust inhibitive polyamide epoxy. Surface preparation shall be thesame as for above ground external coating, of Subsection 2.(2)(e)(iii)1) of this specification.

b) Steel pipe in augured holes, or in a tunnel or casing without annulargrout shall be coated with a two-package polyisocyanate, polyol-cured, 100 percent solids polyurethane coating system conforming toASTM D 16 Type V System, applied to a minimum DFT of 625micrometers.

The coating material shall be Corropipe II-Tx or Corroclad 2000 asmanufactured by Madison Chemical Industries, Inc., or approvedequal, and applied in strict accordance with manufacturer'srecommendations. For external field welds and other field repairs useMadison Chemical "GP" II or "Tx" Touch Up, or approved equal, inaccordance with manufacturer's recommendations.

(3) Ductile-Iron Pipe and Fittings.

(a) Ductile-Iron Pipe, 100 Through 1200 Millimeters. All ductile-iron pipe shallconform to the requirements of AWWA Standard C151. Length shall be no lessthan 5.5 meters long. Unless otherwise specified on the plans, all pipe shall be ofthickness Class 51 regardless of pipe size. Joints shall be of the push-on type orflanged type unless otherwise specified on the plans. Push-on joints shall conformwith the requirements of ASA Specification A21.11 (AWWA C111). Flangedjoints shall conform with the requirements of AWWA C115 including a clothinserted, rubber gasket material 3 millimeter thick for flanged joints. Threaded orgrooved type joints which reduce pipe wall thickness, below the minimumrequired, are not acceptable.

Where restrained joints for buried service are required, the Contractor shall providethe following, or equal:

1. Super-Lock Joint by Clow Corporation.

2. Flex-Ring or Lok-Ring by American Cast Iron Pipe Company.

3. TR-Flex or Field-Lok Joint by U.S. Pipe and Foundry Company.

Restrained joints shall have sufficient distance from each side of the bend, tee,plug, or other fitting to resist thrust developed at the design pressure for the pipe.

Water main interior coatings shall conform to AWWA C104 or ANSI A21.4,cement lined with seal coat.

All material used for internal coating must be NSF 61 and listed as suitable forcontact with potable water as required by Chapter 290, Rules and Regulation for

13-75 50932-97

Public Water Systems, Texas Natural Resources Conservation Commission(TNRCC).

Exterior coating in open cut excavation shall consist of a prime coat and an outsideasphaltic coating conforming to AWWA C110, C115, or C151 for pipe and fittings.The Contractor shall encase the water line in a double wrap of polyethylene.Polyethylene wrap shall conform to the requirements of Subarticles 2.(13),"Polyethylene Film Wrap", and 3.(1), "Polyethylene Film Wrap", of thisspecification. Install bond wire as specified in the item.

Ductile-Iron pipe in augered holes shall be coated with a polyurethane coating.Polyurethane coating shall conform to the same requirements under Subsection2.(2)(e)3., "External Coating" of this specification.

(b) Fittings for Ductile-Iron Pipe. All fittings for use with ductile-iron pipe ofnominal sizes 100 through 1200 millimeters shall conform to AWWA StandardC110 or C153.

Joints shall be of the push-on type or flanged type unless otherwise specified on theplans. Push-on joints shall conform to the requirements of ANSI SpecificationA21.11 (AWWA C111), rated for a 1724 kilopascals working pressure or A21.53(AWWA C153). Flanged fittings shall conform to AWWA C110, the materialshall be cast or ductile iron and conform to ANSI B16.1, class 125 rated at 1724kilopascals working pressure. Flanged fittings shall be screwed on threaded pipeends done in the shop in accordance AWWA C115 for attachment, aligning andfacing.

The inside and outside surfaces of the fittings shall be coated as specified for theregular lengths of ductile Iron pipe.

(4) Cast-Iron Pipe and Fittings.

(a) Cast-Iron Pipe, 100 Through 600 Millimeters. All cast-iron pipe shall conformto the requirements of AWWA Standard C106 or AWWA Standard C108.

Unless otherwise specified on the plans, all pipe shall be of the thickness requiredfor "Laying Condition F" and a minimum of 1.5 meters of cover and the pipe shallbe designed for a minimum working pressure of 1034 kilopascals.

Joints shall be of the push-on type unless otherwise specified on the plans. Push-onjoints shall conform with the requirements of ASA Specification A21.11 (AWWAC111).

The interior and exterior coatings shall be as specified for ductile-iron pipe of thisspecification in Section 2.(3)(a).

(b) Cast-Iron Fittings. Cast-iron or ductile iron fittings shall be permitted, unlessotherwise shown on the plans.

14-75 50932-97

All fittings for use with cast-iron pressure pipe of nominal sizes 100 through 600millimeters shall conform to the requirements of AWWA Standard C110 or C153.The fittings shall be designed for a pressure rating of 1724 kilopascals.

Joints shall be of the push-on type unless otherwise specified on the plans. Push-onjoints shall conform to the requirements of ASA Specification A21.11 (AWWAC111).

The inside and outside surfaces of the fittings shall be coated as specified for theregular lengths of cast-iron pipe.

(5) Polyvinyl Chloride Pipe and Fittings.

(a) Polyvinyl Chloride (PVC) Pipe, 50 Through 400 Millimeters. All PVC pipe 100millimeters and larger shall have integral bell type gasketed push-on joints or shallbe plain end pipe with twin-gasketed couplings conforming to the requirements ofASTM Designation D3139 for push-on-type joints. Rubber gaskets shall conformto the requirements of ASTM Designation D1869.

All PVC pipe furnished shall be marked on the spigot end for proper depth ofmakeup to bell end of a joining length of pipe or fitting.

Valves for use with PVC pipe shall conform to the requirements of Subarticle 2.(9),"Gate Valves, Tapping Valves and Tapping Sleeves", of this specification, exceptthat valve ends shall be of the push-on-joint type for use with PVC pipe. Pipe mustcarry the National Sanitation Foundation Seal (NSF).

(b) Fittings for Polyvinyl Chloride Pipe, 50 Millimeter. All PVC pipe shall bemanufactured in accordance with the requirements of ASTM Designation D1784for PVC 12454B (Type I, Grade 1) or PVC 12454C (Type I, Grade 1) and shallhave a standard thermoplastic pipe dimension ratio (SDR) equal to 21.

All fittings for 50 millimeter PVC shall have a minimum pressure rating of 1379kilopascals. They shall be solvent-weld, socket type conforming to therequirements of ASTM D2466, or gasketed push-on conforming to therequirements of ASTM D2241. All PVC solvent cements shall be manufactured inaccordance with ASTM D2564.

(c) Polyvinyl Chloride Pipe, 100 Through 400 Millimeters. All PVC pipe 100through 300 millimeters shall conform to AWWA C900. All 400 millimeter PVCshall conform to AWWA C905.

It shall be Class 150 DR-18 (100 to 300 millimeters) and class 235 DR-18 (400millimeter) and have cast-iron equivalent outside diameters unless otherwisespecified. It shall be furnished in nominal 6 meter lengths, and shall be marked forproper mate up to adjoining pipe or fitting.

The joints shall conform to the same requirements as those specified for 50millimeter PVC pipe.

15-75 50932-97

(d) Bends and Fittings for PVC Pipe, 100 Through 400 Millimeters. Fittings shallconform to the requirements of Section 2.(3)(b), "Fittings for Ductile-Iron Pipe".They shall be polyethylene wrapped as required by Subarticles 2.(13),"Polyethylene Film Wrap", and 3.(14), "Polyethylene Film Wrap", of thisspecification.

Restrained joints shall have sufficient distance from each side of the bend, tee,plug, or other fitting to resist thrust developed at the design pressure for the pipe.Where preventing movement of pipe 300 millimeters in diameter or greater due tothrust is necessary, provide the following restrained joints, or equal:

1) Fittings: JCM 610 Sur-Grip Fitting Restrainer by JCM Industries, Inc. orSeries 500 Fitting Restrainer by Ebba Iron, Inc., or approved equal.

2) Bell and Spigot: JCM 620 or 621 Sur-Grip Bell Joint Restrainer by JCMIndustries, Inc. or Series 1500 or Series 1100HV Joint Restrainer by Ebba Iron,Inc., or approved equal.

(e) Nonmetallic Pipe Detection. Where nonmetallic pipe is installed longitudinallyunderground a method of detecting the location of the nonmetallic pipe shall berequired. The specific method used shall be as shown on the plans and/or approvedby the Engineer. This system may involve some components to be installed in thetrench around the pipe to be detected using a metal detector. Or the system mayconsist of locating equipment capable of creating a non-destructive pressure wavewhich can be detected above ground using a portable detection device with bothaudible and visual indicators. Either system of detection shall be capable ofaccurately locating the pipe to a maximum depth of one (1) meter over the areasshown on the plans.

Either system must be capable of locating lines under earth, concrete or asphalticsurfaces. The equipment, materials and installation used shall be as specified bythe manufacturer.

(6) Prestressed Concrete Cylinder Pipe and Fittings.

(a) General. The Utility owner's representative or Engineer reserves the right to visitthe manufacturing facilities for prestressed concrete cylinder pipe, without notice.Such inspection will in no sense make the Utility Agency a party to the contract.The review will be to determine compliance with this specification. Such reviewshall not be construed in any way of relieving the Contractor of his responsibilitiesunder this contract.

(b) Prestressed Concrete Cylinder Pipe Design. Prestressed concrete cylinder pipeshall meet the requirements of AWWA C301-84 and AWWA M9, except asmodified herein. Full circumferential welds at joints requiring welding shall beprovided. When specified on the plans, the pipe shall be modified for CathodicProtection in accordance with the Special Specification Item, "Cathodic ProtectionSystems for Large Diameter Water Main".

16-75 50932-97

The pipe design shall be based upon the lesser of the measured properties of thematerial actually used in the manufacture of the pipe or the minimum stated values,required in this specification, for said properties and not generic values.

Pipe and fittings shall be designed per AWWA C301-84 Appendix B, to withstandthe most critical simultaneous application of external loads and internal pressures.The design shall be based on a minimum of AASHTO HS-20 loading (AREA E-80loads where indicated) and depths of bury as indicated. Marston Earth Loads for atransition width trench shall be used in the pipe design for pipe with zero (0) to4.88 meters of cover. Marston's Earth Loads for a trench width of OutsideDiameter (of pipe) plus one (1) meter may be used for pipe with greater than 4.88meters of cover. The unit weight of fill shall be no less than 1922 kilograms percubic meter. Ninety-degree Olander coefficients for the earth load and waterweight contained in the pipe along the 15-degree Olander coefficients for the pipeweight shall be utilized when calculating the moments and thrusts in the pipe wall.The groundwater level shall be assumed to be equal to natural ground surface orcritical conditions.

The allowance for tensile stress in the concrete core or mortar coating at anycombination of external loadings and internal pressures shall not exceed 3.5 timesthe square root of the compressive strength of concrete. The maximum allowablecompressive stress in the concrete core or mortar coating due to any combination ofexternal loads or internal pressures (working and transient) shall be 0.55 times thecompressive strength of concrete.

The internal design pressures are as follows:

Working pressure = 517 kilopascals

Hydrostatic field test pressure = 862 kilopascals

Maximum pressure due to surge = 862 kilopascals

Minimum pressure due to surge (D > 600mm)= 34.5 kilopascals

Modulus of soil reaction (E') = 10.342 megapascals

Bedding constant (K) = 0.586 kilopascals

Deflection lag factor (D) = 6.89 kilopascals

Steel cylinder thickness shall be sufficient for the transfer of these forceslongitudinally along the pipeline.

Pipe from inventory is permitted if all specifications and certifications can be met.Testing records required by specifications must be provided.

(c) Prestressing Wire. Prestress wire must be furnished from an independentmanufacturer (i.e., a manufacturer with no legal or financial ties to the pipemanufacturer). Foreign manufactured wire shall be tested by a local independentlaboratory at the Contractor's expense.

17-75 50932-97

All mechanical tests required in ASTM A648 shall be performed by the wiremanufacturer on a sample taken from one (1) end of each coil and selected to berepresentative of normal wire drawing conditions. The pipe manufacturer shall testa sample, for all mechanical requirements, from one (1) of each five (5)consecutively produced coils or fraction thereof in each lot.

The pipe manufacturer shall require that the wire manufacturer submit certifiedresults of chemical and mechanical tests, performed by the wire manufacturer.Mechanical test shall be performed by the pipe manufacturer. The pipemanufacturer shall attest to such in his affidavit of compliance.

Tests of all prestressing wire are to be submitted for record purposes, indicatingcompliance with the specifications. Submission of the test specimens is notrequired. The expense of the tests shall be borne by manufacturer.

The surface temperature of the prestressing wire at any point in the drawing processshall not exceed 182 degrees Celsius. The wire manufacturer shall audit the surfacetemperature of the wire throughout the length of the wire drawing process daily foreach working shift producing ASTM A648 wire, or shall take similar dependableprecautions to provide the maximum wire surface temperature is not exceeded.

(i) Preparation of Prestressed Concrete Pipe for Bonding:

1) Fabrication: Prestressed concrete pipe used for this project shall befabricated in such a manner as to establish electrical continuity betweenmetallic components of the pipe and the joints.

2) Acceptable Methods: Establish electrical continuity as indicated in theplans and specifications.

3) Criteria for Electric Continuity:

a.) Tensile Wire: The pipe manufacturer shall obtain a resistance nogreater than 0.03 ohms between any wire and the steel joint ring at theend of the pipe farthest from that wire. The manufacturer shall statethe values obtained and the method of such measurements.

b.) Internal Pipe Joint Components: The pipe manufacturer shall obtain aresistance of less than 0.03 ohms between any component and thesteel pipe cylinder.

4) Tensile Wire Continuity:

a.) Continuity between the tensile wire coils and the steel cylinder shallbe accomplished by tightly wrapping the tensile wire overlongitudinal mild steel straps placed in the mortar during pipe coremanufacture.

1) Two continuous straps 180 degrees apart shall be used andinstalled longitudinally along the pipe. These straps mustmaintain electrical continuity between metallic components.

18-75 50932-97

2) The steel straps shall be mild steel or equal and free of grease,mill scale or other high resistance deposits.

3) The longitudinal straps shall be made electrically continuous withthe pipe cylinder by steel fasteners of suitable dimensions placedbetween the steel cylinder and longitudinal straps. The fastenersmust be adequately connected so as to remain intact during thepipe fabrication process.

4) The steel straps shall be securely connected to the joint rings andshall extend to the piping surface, to allow connection of twobonding jumpers across each pipe joint.

5) Steel Cylinder Continuity:

a.) Continuity of joint components and the steel cylinder shall beestablished. These components include the following:

1) Anchor socket brackets.

2) Anchor socket.

3) Spigot ring.

4) Bell ring.

b.) If mechanical contact does not provide a resistance of less than 0.03ohms between components, the components shall be tack welded toprovide electrical continuity.

(d) Prestressed Concrete Cylinder Pipe. The pipe joints shall be rubber gasketed orwelded bell-and-spigot type except where flanged joints are required for valves andfittings as shown on the plans. In jacking, boring, tunneling or augeringinstallations, the outside diameter of the pipe shall have a constant outside diameterfrom bell to spigot end. The Contractor is responsible for designing the pipe andpipe joints to carry all loads including but not limited to: overburden and lateralearth pressures; subsurface soil and water loads; grouting; other conditions ofservice; thrust of jacks, and any stress anticipated during the handling andinstallation of the pipe. See paragraphs referring to joints and jointing foradditional requirements. Rubber gasket material for rubber gasketed bell andspigot joints shall be in accordance with AWWA C301-84.

All rubber gasketed joints shall be bonded as shown on the plans to provideelectrical continuity along the entire pipeline except where insulating flanges arecalled for.

A design pressure 1.5 times the pressure class (working pressure)is required.Restrain joints by welding or harnessing joints. Harnessed joints shall be AWWAM9, clamp or snap ring type. Increase longitudinal steel area (cylinder thickness)to prevent cylinder stress from exceeding 40 percent of minimum yield point atrated working pressure and 67 percent of minimum yield point at rated maximum

19-75 50932-97

surge pressure where pipe and fittings are subjected to longitudinal stresses inducedby restrained joints or thrust blocks.

Pipe sections shall be provided in standard lengths with a minimum of 4.88 metersexcept for special fittings or closure sections as indicated on the shop drawings.Each pipe section shall be clearly marked to show locations and pipe pressure.

(e) Fittings and Specials for Prestressed Concrete Cylinder Pipe. The Contractorshall furnish all fittings and specials (bends and elbows) required for bends,branches, access manholes, air valve and blowoff connections, and connections toline valves and other fittings. Fittings and specials shall be designed in accordancewith the design details and AWWA C301. Fittings and specials are subject to thesame internal and external loads as the straight pipe. Fabricated fittings from pipesections, may use steel pipe welded to proper shape, coated and lined with wirereinforced cement mortar. Provide fabricated bends or fittings with a minimumradius of two and one-half (2-1/2) times the pipe diameter.

Curves and bends shall be made by deflecting the joints, by use of beveled joints,or by a combination of the two (2) methods, unless otherwise indicated on theplans. The Contractor may submit details of other methods of producing curvesand bends for consideration by the Engineer, and if deemed satisfactory, shall beinstalled at no additional cost.

All pipe flanges shall conform to AWWA C207 requirements for standard steelflanges of the pressure class corresponding to the pipe class.

All exposed steel parts of flanges and bolts, shall be coated as specified by thesection for steel pipe of this specification.

(f) Grout for Joints. See Subarticle 2.(17), "Grout for Prestressed Concrete CylinderPipe Joints", of this specification for requirements on grout for joints.

(g) Manufacturer's Quality Control.

(i) Hydrostatic Test. Pipe cylinders shall be hydrostatically tested at thefactory in accordance with AWWA C301-84, Section 3.5.3. Thehydrostatic pressure shall be held for a minimum of 15 minutes for athorough inspection of the pipe. Any pipe revealing cracks in the mortarcoating shall be rejected.

(ii) Proof of Design Tests. The design of each size and class of concretecylinder pipe shall be verified by tests conducted on representativespecimens. The tests described in this paragraph are for proof of designonly. It is not necessary that these tests be made on pipe manufacturedspecifically for this contract. Certified reports covering tests made onother pipe of the same size and design as specified herein andmanufactured from materials of equivalent type and quality may beaccepted as adequate proof of design.

20-75 50932-97

Additionally, one (1) pipe from each design class shall be tested in a 3-edge bearing test to an equivalent load of the earth load plus live loadings.No cracks shall be permitted on the inside of the core.

If any cracks are found, two (2) more samples from that design class shallbe tested; and if no cracks are found, the lot of pipe from that class shallbe accepted. If either of the two (2) additional tests fail, the lot shall berejected. The manufacturer may elect to test each pipe from a failed lotand any individual pipe that does not fail shall be accepted. Writtencertification and a copy of all test reports shall be submitted.

(iii) Absorption Test. A water absorption test shall be performed on samplesof cured mortar coating taken from each working shift. The mortarcoating samples shall have been cured in the same manner as the pipe. Atest value shall consist of the average of a minimum of three (3) samplestaken from the same working shift. The test method shall be inaccordance with ASTM C497, Method A. The average absorption valuefor any test shall not exceed nine (9) percent and no individual sampleshall have an absorption exceeding 11 percent.

Tests for each working shift shall be performed on a daily basis untilconformance with the absorption requirements has been established basedupon the passing of 10 consecutive tests, at which time testing may beperformed on a weekly basis for each working shift. With failingabsorption test results, daily testing shall be resumed for each workingshift and shall be maintained until conformance to the absorptionrequirements is reestablished by 10 consecutive passing tests.

(7) Joint Bonding and Electrical Insulation. Electrical bond wires shall be a minimumNo. 2 AWG, seven (7) strand, copper cable, furnished with high molecular weightpolyethylene insulation (HMWPE). 25 millimeters of HMWPE insulation shall beremoved from each end of the bond wire. The minimum number of bond wires shall beprovided as shown on the plans for steel or ductile-iron pipe.

Three ASTM 366 steel bonding clips, each approximately 3.3 millimeters thick, 63.5millimeters long, and 31.5 millimeters wide, shall be welded with 3 millimeter filetwelds to the bell and spigot of adjacent unwelded prestressed concrete cylinder pipe orsteel pipe with rubber gasketed joints. The clips shall be manufactured so electricalcontinuity will be maintained regardless of small deflections of finished (mortared)joints.

Electrical Flange insulation shall be provided through the installation of the followingmaterials:

(a) Insulating Gasket:

(i) For piping sized 750 millimeters in diameter and greater, provide PyroxG-10 with nitrile seal, Type E LineBacker gasket as manufactured byPipeline Seal and Insulator, Inc., or approved equal.

21-75 50932-97

(ii) For piping sized between 300 and 600 millimeters in diameter, providePhenolic PSI with nitrile seal, Type E LineBacker gasket as manufacturedby Pipeline Seal and Insulator, Inc., or approved equal.

(iii) The Contractor may provide a plain-faced phenolic gasket, asmanufactured by Pipeline Seal and Insulator, Inc., or approved equal. Thephenolic gasket shall placed between two full-faced gaskets. Providecloth-inserted rubber gasket material, 3.175 millimeter thick in accordancewith AWWA C207. Gaskets shall be factory cut to proper dimensions.

(b) Sleeves and Washers:

(i) For piping sized 750 millimeters in diameter and greater, provide fulllength mylar sleeves with Pyrox G-10 washers, double washer sets asmanufactured by Pipeline Seal and Insulator Inc., or approved equal.

(ii) For piping sized between 300 and 600 millimeters in diameter, providefull length mylar sleeves with phenolic washers, double washer sets asmanufactured by Pipeline Seal and Insulator, Inc., or approved equal.

(8) Copper Tubing for Copper Service Lines and Small Mains. All 19 millimeter, 25millimeter, 38 millimeter and 50 millimeter diameter copper tubing for undergroundservice shall be Type "K" soft annealed and seamless with the proper bending temperand shall conform to ASTM Designation B88 and Federal Specification WW-T-799with the following exceptions:

Section 14 of ASTM Designation B88 is hereby modified to provide for the followingnumber of samples for each size of tubing:

For each 2286 meters of tubing ….............one (1) sample

Items of less than 2286 meters of tubing ...one (1) sample

19 millimeter and 25 millimeter tubes shall be furnished in coils, each containing 18.3meters. 38 millimeter and 50 millimeter tubes shall be furnished in coils of minimum12 meter lengths. Minimum joint spacing shall be in multiples of 18 meters or 12meters respectively.

(9) Brass Fittings for Underground Services Lines and Small Mains.

(a) General. Unless otherwise provided herein, brass fittings will be required inunderground installations of service lines and small mains in the water distributionsystem.

Brass fittings shall be composed of Copper Alloy No.C 83600 conforming to therequirements of ASTM Designation B62. The general pattern for each fitting shallconform to that of standard brass fittings as manufactured by Mueller Company,Hays Manufacturing Company or an approved equal.

22-75 50932-97

Compression fittings may be used for unions except where they occur underexisting or future paving. Compression tube fittings shall have Buna-N beveledgaskets.

Each fitting shall have the manufacturer's name or trademark and size plainlystamped into or cast on the body. Pipe adjacent to fittings shall be straight for atleast 250 millimeters.

Waterways shall not be smaller in diameter than the nominal size of the stop andshall be accurately finished to a watertight joint; all nuts and washers shall be facedto a true fit; and the design shall be such that the joint will remain watertight andreasonably easy to operate after repeated use over a number of years. All externalthreads shall conform with AWWA Standard C800 and, on corporation stops, shallbe protected in shipment by plastic coatings or an alternate approved method.

(b) Corporation Stops. Inlet ends shall be of one of the following types:

Standard corporation stop threads as specified in Table 1, AWWA C800; iron pipethread (permissible for use with service saddles only) or Hays 4200-4202 orapproved equal.

The valve body shall be of one of the following types: Tapered plug type; "O-ring"seat ball type; or the rubber seat ball type.

Outlet ends shall be a flared-copper connection for use with type-k, soft copper orcompression type fitting.

For PVC pipe, corporation stops shall be all brass and specifically designed for usewith PVC pipe.

(c) Curb Stops. Inlet ends shall have flared copper connections or compression typefittings.

The valve body shall be of straight through or angled meter stop design equippedwith padlock wings and shall be of the "O-ring" seal straight plug type or therubber seat ball type.

The outlet shall have female iron pipe threads or swivel nut meter spud threads on19 millimeter and 25 millimeter stops and shall have two hole flanges for 38millimeter and 50 millimeter sizes.

(d) Service Saddles. Service saddles shall have dual straps and shall consist of one ofthe following types: Brass body and straps; ductile-iron body and straps, vinylcoated; ductile- iron body, vinyl coated with stainless steel straps.

Taps for PVC Water Mains: Use dual strap or single, wide band strap saddleswhich provide full support around the circumference of the pipe and bearing area ofsufficient width along the axis of the pipe 50 millimeters minimum, ensuring thatthe pipe will not be distorted when the saddle is tightened. Use Romac Series101N wide band, stainless- steel tapping saddle with AWWA standard thread(Mueller thread) or equal.

23-75 50932-97

(e) Angle Stops. Angle stops shall be in accordance with AWWA C800; ground-key,stop type with bronze lock-wing head stop cap; inlet and outlet threads shallconform to the application tables of AWWA C800; and inlet side shall be a flaredconnection or Mueller 110 compression type or an approved equal.

1. Outlet for 19 millimeter and 25 millimeter sizes: Meter swivel nut with saddlesupport.

2. Outlet for 38 millimeter through 50 millimeter sizes: "O-ring" sealed meterflange, iron pipe threads.

(f) Fittings. Fittings shall be in accordance with AWWA C800 and as describedbelow:

1) Castings: Smooth, free from burrs, scales, blisters, sand holes, and defectswhich would make them unfit for intended use.

2) Nuts: Smooth cast and have symmetrical hexagonal wrench flats.

3) Flare-joint fittings: Smooth cast. Seating surfaces for metal-to-metal seal shallbe machined to proper taper or curve, free from any pits or protrusions.

4) Thread fittings, of all types, shall have N.P.T. Threads, and male threaded endsshall be protected in shipment by plastic coating or other equally satisfactorymeans.

5) Compression tube fittings shall have Buna-N beveled gasket.

Brass fittings will require the following factory testing:

1) Submerge in water for 10 seconds at 586 kilopascals with stops in both closedand open positions.

2) Reject any fittings that show air leakage. The State may confirm tests locally.An entire lot from which samples were taken will be rejected when randomsampling discloses unsatisfactory fittings.

(10) Gate Valves, Tapping Valves and Tapping Sleeves.

(a) Gate Valves. Gate valves shall conform to AWWA Standard C500, C509 and thefollowing supplemental specifications:

Valves used in direct bury and in subsurface vaults shall open clockwise andabove-ground valves shall open counter clockwise.

If type of valve is not indicated on the plans, gate valves shall be used as linevalves for sizes less than 400 millimeters. If type of valve is specified, nosubstitute will be allowed.

The valve body shall be straight-through or angled, meter-stop design equippedwith the following:

24-75 50932-97

1) "O-Ring" seal straight plug type.

2) Rubber seat ball type.

The outlet end shall be female, iron-pipe thread or swivel-nut, meter-spud thread on19 millimeter and 25 millimeter stops and 2-hole flange on 38 millimeter and 50millimeter sizes.

(i) Gate valves 38 millimeters diameter and smaller shall have an operatingpressure of 862 kilopascals; bronze mounting; rising-stem; single-wedge;disc type; screwed ends; Crane No. 428, or equal.

(ii) Gate valves 50 millimeters in diameter shall have an iron body; doublegate; non-rising stem; 68 kilogram test; 50 millimeter square nut operatingclockwise to open.

(iii) Gate valves 100 to 300 millimeters in diameter shall be non-directional;and resilient seated in accordance with (AWWA C509) or parallel seatdouble disc in accordance with (AWWA C500);operating pressure of1379 kilopascals; bronze mounting; push- on bell ends with rubber jointrings and nut operated unless otherwise specified; resilient seated provideby American Darling AFC-500, US Pipe Metroseal 200 or approvedequal; double disc provided by American Darling 52, Clow F-6102 orapproved equal; and comply with following:

1) Design: Fully encapsulated rubber wedge or rubber seat ringmechanically attached with minimum 304 stainless steel fasteners orscrews; threaded connection isolated from water by compressedrubber around opening.

2) Body: Cast or ductile iron; flange bonnet and stuffing box togetherwith ASTM A307 Grade B bolts. Cast in body manufacturer'sinitials, pressure rating, and year manufactured.

3) Bronze: Valve components in waterway shall contain not more than15 percent zinc and not more than 2 percent aluminum.

4) Stems: ASTM B763 bronze, alloy number 995 minimum yieldstrength of 275.8 megapascals; minimum elongation in 50 millimetersof 12 percent; non-rising.

5) "O-rings": AWWA C509, Sections 2.2.6 and 4.8.2.

6) Stem Seals: Consist of three (3) "O-rings", two (2) above and one (1)below the thrust collar with an anti-friction washer located above thethrust collar.

7) Stem Nut: Independent or integrally cast of ASTM B62 bronze.

8) Resilient Wedge: Molded; synthetic rubber; vulcanized and bondedto cast or ductile iron wedge tested to meet or exceed ASTM D429

25-75 50932-97

Method B; or attached with 304 stainless steel screws; seat againstepoxy-coated surface in valve body.

9) Bolts: AWWA C509 Section 2.2.5; stainless steel; cadmium plated,or zinc coated.

(iv) Gate valves 350 to 600 millimeters diameter shall be in accordance withAWWA C500; push-on bell ends with rubber rings and nut operatedunless otherwise specified; double disc; 1034 kilopascals; and complywith following:

1) Body: Cast or ductile iron; flange together bonnet and stuffing boxwith ASTM A307 Grade B bolts. Cast in body manufacturer'sinitials, pressure rating, and year manufactured. Equip with rollers,tracks and scrapers.

2) Stems: Machined from ASTM B62 bronze rod with an integralforged thrust collar machined to size; non-rising.

3) Stem Seals: Consist of one (1) "O-ring" above and one (1) "O-ring"below the thrust collar with an anti-friction washer located above thethrust collar for operating torque.

4) Stem Nut: Independent or integrally cast of ASTM B62 bronze.

5) Discs: Cast iron with bronze disc rings securely peened intomachined dovetailed grooves.

6) Wedging Device: Solid bronze or cast-iron, bronze-mounted wedges.Thin plates or shapes integrally cast into cast-iron surfaces areacceptable. Other moving surfaces integral to wedging action shall bebronze monel or nickel alloy-to-iron.

7) Bronze Mounting: Built as integral unit mounted over, or supportedon, cast-iron base and of sufficient dimensions to be structurallysound and adequate for forces which will be imposed on it.

8) Gear Cases: Cast iron; furnished on all valves 450 millimeters andlarger and of extended type with steel side plates; lubricated; gearcase enclosed with oil seal or "O-rings" at all shaft openings.

9) Stuffing Boxes: Located on top of bonnet and outside gear case.

(v) Gate valves 500 millimeter and larger shall be furnished and equippedwith bypass valves.

1) Provide 75 millimeters bypass valves for 500 millimeter gate valves.2) Provide 100 millimeter bypass valves for 600 millimeter gate valves.

Valves 100 through 300 millimeters for installation in vertical pipe lines shallhave double disc, square bottom.

26-75 50932-97

Valves 350 millimeters and larger for installation in vertical pipe lines shall beequipped with bronze shoes and slides.

Gate valves installed at depths greater than 1.2 meters shall provide non-rising,extension stem having coupling sufficient to attach securely to operating nut ofvalve. The upper end of the extension stem shall terminate in a square wrenchnut no deeper than 1.2 meters from finished grade.

Gate valves in factory mutual type meter installations shall conform to theprovisions of this specification with outside screw and yoke valves and shouldcarry the label of Underwriters' Laboratories, Inc.

Coatings shall be in accordance with AWWA C550; Indurall 3300 or approvedequal and be: Non-toxic; not impart taste to water; function as physical,chemical, and electrical barrier between base metal and surroundings;minimum 300 micrometers thick; fusion-bonded epoxy; prior to assembly ofvalve, apply protective coating to interior and exterior surfaces of body.

Provide flange joints when the valve is connected to steel or prestressedconcrete cylinder pipe.

(b) Tapping Valves. Tapping valves shall be double disc type and meet all therequirements of gate valves, as listed above, except for the type of joints; inletflanges shall meet AWWA C110, Class 125 or shall meet AWWA C110, Class 150or higher and have a minimum eight-hole flange. Outlets shall have standardmechanical or push-on type joints which shall fit any standard tapping machine.

The valve seat opening shall be such that a full size shell cutter for the nominal sizetap may pass through the valve without any contact with the valve body.

Valve boxes shall be furnished and installed as required by this specification.

(c) Tapping Sleeves. Tapping sleeve bodies shall be in accordance with AWWAC110 cast or ductile iron; or AWWA C111 carbon steel; in two (2) sections to bebolted together with high-strength, corrosion-resistant, low-alloy, steel bolts andshall have mechanical joint ends.

Branch outlets of tapping sleeves shall be flanged; machined recess in accordanceAWWA C207 Class D, ANSI 68 kilogram drilling. The gasket shall be affixedaround recess of the tap opening to preclude rolling or binding during installation.

Steel sleeves shall not be used for taps greater than 75 percent of pipe diameter.

Welded steel tapping sleeve bodies may be used in lieu of cast-iron or ductile iron,subject to the following limitations and requirements:

Flanges shall be AWWA C207, Class D, ANSI 68 kilogram drilling. Gasket shallbe affixed around recess of tap opening to preclude rolling or binding duringinstallation.

27-75 50932-97

Steel sleeves are restricted to use on pipes sizes 150 millimeters and larger. No"size-on-size" sleeve will be permitted (i.e., 150 millimeters x 150 millimeters,etc.). To accomplish size-on-size connections, the next smaller tap may be madeand a LEB (large end bell) increaser used. Where fire service from a 150millimeter main is approved, a cast-iron split sleeve only will be permitted.

The body shall be of heavy welded steel construction. The top half of the bodyshall be grooved to permanently retain a neoprene "O-ring" seal against the outsidediameter of the pipe.

Steel sleeves shall be fusion-bonded epoxy coated to a minimum 300 micrometersthickness. The finished epoxy coat shall be free of laminations and blisters; notpeel; remain pliant and resistant to impact. Ship steel sleeves in wooden crates thatprovide protection from damage to epoxy coating during transport and storage.

Bolts and nuts shall conform to AWWA Standard C500, Section 3.5, and shall becoated with a 100 percent vinyl resin (or shall be made of corrosion resistantmaterial).

Tapping sleeves shall be provided with a 19 millimeter NPT test opening for testingprior to tapping. Provide a 19 millimeter bronze plug for the opening.

Steel tapping sleeves shall be Smith Blair No. 622, Rockwell No. 623, JCM No.412 or approved equal.

(d) Air Release and Vacuum Relief Valve. Combination air valves shown on theplans, means combination valves designed to fulfill the functions of air release(permitting escape of air accumulated in the line at the high point of elevation whilethe line is under pressure) and vacuum relief. Air release and vacuum relief valves200 millimeters and smaller in diameter shall be self-contained in one (1) unit.

(i) Air release valves shall be provided with flanged inlet and outletconnections as specified on the plans. For 50 millimeter and 75 millimetersingle body valves, the orifice should be sized for 689 kilopascals workingpressure. The air relief valve shall be constructed of materials as follows:body and cover, ASTM A 48, Class 30 cast iron; float and leveragemechanism, ASTM A 240 or A 276 stainless steel; orifice and seat shallbe stainless steel against Buna-N or viton mechanically retained with hexhead nut and bolt. All other valve internals shall be stainless steel orbronze. Valve exterior shall be painted with an epoxy shop-appliedprimer. Provide Apco Model 200 or GA Industries Fig. 2-AR or approvedequal.

(ii) Air Release and Vacuum Valves shall be single-body, standardcombination or duplex-body custom combination valves as shown on theplans.

1) For 50 and 75 millimeter, single-body valves, provide inlet and outletsizes as shown on the plans and an orifice sized for a 689 kilopascalsworking pressure. Valve materials: Body, cover and baffle, ASTM

28-75 50932-97

A48, Class 35, or ASTM A126, Grade B cast iron; plug or poppet,ASTM A276 stainless steel; float, ASTM A240 stainless steel; seat,Buna-N; other valve internals shall be stainless steel. Valve exteriorshall be painted with an epoxy shop-applied primer. Provide ApcoModel 145C or 147C, Val-Matic Series 200, or approved equal.

2) For 75 millimeter and larger duplex body valves as shown on theplans, provide an Apco Series 1700 with a No. 200 air release valve,GA Industries Fig. No. AR/GH-21K/280, or equal. Air and vacuumvalve materials: Body and cover, ASTM A48, Class 35, cast iron;float, ASTM A240 stainless steel; seat, Type-304, stainless steel andBuna-N; other valve internals, stainless steel or bronze. Air releasevalve: Constructed as specified in previous paragraph above on AirRelease Valves.

Valve boxes shall conform to the requirements of Subarticle 2.(11),"Valve Boxes", of this specification.

(e) External Coating Above Ground Valves. Coat valves with a polyurethanecoating conforming to the same requirements under Paragraphs 2.(2)(e)(iii)3.b.

(11) Butterfly Valves. Butterfly valves and operators shall conform to the requirements ofAWWA Standard C504 Class 150B, except as modified or supplemented herein.

Valves shall be short-body, flanged design for closing against a flow velocity of 4.88meters per second at a normal working pressure of 1034 kilopascals and with adownstream pressure of zero (0) kilopascals (Class 150B).

Direct-bury valves and valves in subsurface vaults shall open clockwise. All above-ground and plant valves shall open counter clockwise.

Body shall be cast iron, ASTM 126, Class B.

Discs for valves 300 millimeters in size and smaller shall be ASTM A435, Type 1 (Ni-Resist), cast iron disc with ni-chrome edge (Pratt TM) or ductile iron with Type 304 orType 316 stainless steel mating edge. Discs for valves 350 millimeters and larger shallbe cast iron or ductile iron.

Valves shall have Buna-N or neoprene seats mounted either on the disc or in the body.The seats shall be mechanically secured and may not rely solely on adhesive propertiesof epoxy or similar bonding agents to attach the seats to the body. Seats on the discshall be mechanically retained by Stainless Steel (18-8) retaining rings held in place bystainless steel (18-8) cap screws that pass through a rubber seat for added retention.When the seat is on the disc, the seat shall be retained in position by shoulders locatedon both the disc and the stainless-steel retaining ring. Mating surfaces for seats shall beType 304, or 316, stainless steel and secured to the disc by mechanical means. Sprayedon or plated mating surfaces will not be allowed. The disc shall be cast-ironconforming to ASTM A126, Class B or ductile-iron conforming to AWWA C151.

Coat all interior wetted ferrous surfaces of valve, including disc, with epoxy suitable forpotable-water conditions. Epoxy, surface preparation, and epoxy application shall be in

29-75 50932-97

accordance with AWWA C550 and coating manufacturer's recommendations. Providetwo (2) coats of two-component, high- build epoxy with minimum dry thickness of 250micrometers. Epoxy coating shall be Indurall 3300 or equal. Coatings shall be holidaytested and measured for thickness.

Valve shaft and keys, dowel pins, or taper pins used for attaching valve shaft to valvedisc shall be Type-304 or 316 stainless steel. All portions of shaft bearings: Stainlesssteel, bronze, nylon, or Teflon (supported by fiberglass mat or backing material withproven record of preventing Teflon flow under load) in accordance with AWWA C504.

Packing shall be field-adjustable, split-V type, and replaceable without removingoperator assembly.

Retaining hardware for seats shall be Type-304 or 316 stainless steel. Nuts and screwsused with clamps and discs for rubber seats: Securely held with locktight, or otherapproved method, from loosening by vibration or cavitational effects.

Valve disc shall seat in a position 90 degrees to the pipe axis and shall rotate 90 degreesbetween full-open and tight-closed position. Install valves with valve shafts horizontaland the convex side of the disc facing the anticipated direction of flow, except whereshown otherwise on the plans.

Joint types for installation with cast-iron or ductile-iron pipe shall be push-on or flanged(flanged valves coupled to Bell- Flange adapters may be used). Flanges shall conformin dimensions and drilling to ANSI B16.1 for cast-iron body valves, Class 125. Boltsconforming to AWWA Standard C500, Section 9, shall be used in all valveinstallations, including bolts for operators, housing, etc. Flanged joints shall be used forall steel or concrete steel cylinder pipe.

Actuators for valves shall be properly sized gear type for valves 200 millimeters andlarger. Gear Actuators shall be fully enclosed and traveling-nut type, rack and piniontype, or worm-gear type. Direct bury valves shall be equipped with a 50 millimetersquare nut operating clockwise to open the valve. The space between the actuatorhousing and the valve body shall be completely enclosed. No moving parts shall beexposed to the soil or elements. Actuators shall be oil tight and water tight, and shall befactory packed with a suitable grease. Operators shall conform to the requirements ofAWWA Standard C504 and shall be equipped with adjustable limit stop devices.

Design for worm-gear and traveling-nut operators shall be such that a torque of 203Newton-meters, or less, will operate valve at the most adverse condition for whichvalve is designed. Vertical axis of operating nut shall not move as valve is opened orclosed.

Butterfly valves shall be used as line valves in lieu of gate valves in sizes 400millimeter, 500 millimeter and 600 millimeter, except where valve type is specified onthe plans, and shall be used exclusively in sizes larger than 600 millimeters.

(12) Valve Boxes. Provide Type "A", cast iron, slide-type valve boxes as manufactured byBass and Hays Foundry, Inc. or approved equal. The chemical composition of Casting"A" shall conform to the requirements of AWWA Standard C110. The base of each

30-75 50932-97

valve box shall be 150 millimeter cast-iron or ductile iron pipe, conforming to therequirements of this Special Specification except that the lining and coating will complywith this section.

Cast a letter "W" into lid, 13 millimeters in height and raised 2.5 millimeters, for valvesserving potable water lines.

Coat boxes, bases, and lids by dipping in hot bituminous varnish.

(13) Fire Hydrants.

(a) General. Fire hydrants shall conform to the requirements of AWWA C502, exceptas modified or supplemented herein. They shall be of dry-barrel, tamper resistant,and collision-safety construction design. Hydrants shall be from samemanufacturer throughout project.

Installation of used, salvaged, or reconditioned fire hydrants will not be permittedunless otherwise shown on the plans.

(b) Hydrant Barrel. The lower hydrant barrel shall be fabricated as a single piece,and shall be connected to the upper hydrant barrel by means of a joint coupling thatwill provide 360 degree rotation of the upper barrel. Clearly mark the finish gradeon the barrel. The bury length shall be as specified and shall be the distance fromthe bottom of the inlet to the ground line.

The hydrant barrel shall be provided with a non-tapped, non corrodible drain ordrip valve, completely of bronze or bronze lined. The drain valve shall operate,automatically and positively, to drain the barrel when the hydrant valve is in thefully-closed position and to completely close the drain opening so as to preventleaking when the hydrant valve is in the open position.

Each hydrant barrel shall be equipped with two (2) 63 millimeter nominal insidediameter hose nozzles and one (1) 100 millimeter nominal inside diameter pumpernozzle conforming with National (American) Standard Fire Hose Coupling ScrewThreads, bronze (minimum Grade D) (per NFPA No. 194 and ANSI B26-1925).

Field-replaceable nozzles shall be securely fastened into the upper barrel bymechanical means, installed by turning counterclockwise, sealed with "O-rings"and shall be mechanically locked in place with a security device. All nozzles shallbe provided with nozzle caps and neoprene gasket seals. The caps shall be securelyattached to the hydrant barrel with chains of not less than 3 millimeters diameter.The pumper nozzle shall be so situated as to allow an unobstructed radius of 250millimeters from the threaded surface of the nozzle throughout the path of travel ofa wrench or other device used to fasten a hose to the nozzle.

The hydrant shall be oriented so that the pumper nozzle faces the curb or streetnearest the hydrant.

The barrel joint connecting the upper and lower hydrant sections shall be designedso that the hydrant shut-off valve will remain closed and reasonably tight againstleakage in the event of an impact accident resulting in damage or breaking of the

31-75 50932-97

hydrant above or near ground level. The joint shall be provided with a breakablebolt flange or breakable coupling that will include an adequate number of bolts,above finish grade.

The operating and hold down nuts shall be fabricated of stainless steel, cast iron orductile iron with bronze inserts. Provide a security device with each hydrantemploying a bronze operating nut to protect this feature of the hydrant frommalicious mischief or unauthorized removal. Any such security devices shall notrequire a special tool for normal off/on operation of the hydrant. The operating nutshall be tapered pentagon 38 millimeters point to face at base, and 28.5 millimeterspoint to face at top of nut, open left (counter clockwise). Hold down assembliesshall be fabricated of suitable metallic materials for the service intended.

The hydrant barrel shall be designed to permit the use of one or more standardextensions, which shall be available from the hydrant manufacturer, in lengths from150 millimeters to 1500 millimeters in 150 millimeter increments.

(c) Shut-off Valve and Inlet Shoe. Hydrants shall have circular, compression-typeshut-off valves which close with the water pressure, with center stem constructionand which remains closed and tight against leakage upon impact. Each shut-offvalve shall be circular and not less than 133 millimeters in diameter. Seal bottomend of stem threads from contact with water with cap nut. The valve seat ring shallbe bronze, threaded into a bronze drain ring to provide an all-bronze drainway. Theseat ring and main valve assembly shall be such that it can be removed from aboveground through the upper barrel by means of a light-weight seat removal wrench.The valve seat facing shall be constructed of molded rubber having a Durometerrating of 90 plus or minus five (5), and shall be a minimum thickness of 13millimeters and resistant to microbiological attack.

Unless otherwise specified on the plans the hydrant inlet shoe shall be an elbowwith AWWA Standard bell designed for a nominal 150 millimeter mechanical jointhub end, or push-on assembly as specified. The hydrant shoe shall be of cast orductile iron pipe and be flanged, swivel or slip joint with harnessing lugs forrestrained joints. Coat interior of shoe with a minimum 300 micrometers of fusion-bonded epoxy conforming to NSF Standard 61. Underground flanging shallincorporate minimum of six (6) full 3/4-inch diameter electro-galvanized orcadmium coated steel bolts or four (4) 5/8-inch diameter stainless or cadmiumcoated steel bolts.

(d) Valve Stem. The operating stems shall be Everdur, or other high-quality non-corrodible metal where threads are located in barrel or waterway. Bronze-to-bronze working parts in waterway; genuine wrought-iron or steel where threads arenot located in barrel or waterway, bronze bushed at penetration of stuffing box; sealthreads against contact with water regardless of open or closed position of mainvalve. The valve stem shall be provided with a breakable stem coupling oppositethe barrel breakaway feature. Connecting pins and locking devices shall beconstructed of bronze or other corrosion-resistant material. The valve stem shall beprovided with a bronze sleeve, "O-ring" seals and travel stop. Operating threads,working parts and bearing surfaces shall be fully lubricated during normal

32-75 50932-97

operation of fire hydrant. The lubricant shall be contained in a lubricating reservoirwhich shall be sealed at the top and bottom. The operating assembly shall beequipped with a thrust bearing or lubricated thrust collar to minimize operatingtorque. The lubricant shall meet the requirements of FDA 21 CFR 178.3570 and bemanufactured with FDA approved oxidation inhibitors.

The valve stem shall operate to open counterclockwise (turning to the left).

(e) Gaskets and Seals. All dynamic seals shall be "O-ring" type, oil-resistantmaterial, which does not require adjustment for a watertight seal. All moving partsin contact with the seal shall be bronze or other corrosion-resistant material.

Static seals shall Buna "N", or other approved synthetic composition.

(f) Painting. Fire hydrant's exterior shall be shop coated with one (1) coat of rustprohibitive primer. Top half of the hydrant from the traffic flange up shall receiveone (1) coat of blue enamel prior to delivery to the job site as outlined by thefollowing:

(i) Exterior Above Traffic Flange (Including Bolts & Nuts). Surfacepreparation shall be in accordance with SSPC-SP10(NACE 2), near whiteblast cleaned surface.

Coated with a three-coat alkyd/silicone alkyd system with a total dry filmthickness (DFT) of 150-225 micrometers as follows:

Prime Coat - Oil Modified Alkyd Primer, Acro Products No. 1104, HeavyDuty Tank & Steel Primer, or approved equal, shall be in generalconformance with SSPC Paint Specification No. 25. Total dry filmthickness (DFT) of 50-75 micrometers.

Intermediate Coat - Heavy Duty Industrial Alkyd Enamel, Acro ProductsNo. 2214, or approved equal, shall be in general conformance with SSPCPaint Specification No. 104, and Federal Standard TT-E-489. Total dryfilm thickness (DFT) of 50-75 micrometers.

Finish Coat - Silicone Alkyd REsin Enamel, Acro Products No. 2215, orapproved equal, shall be in general conformance with SSPC PaintSpecification No. 21. Total dry film thickness (DFT) of 50-75micrometers. Except the hydrant bonnet shall not be finish shop coated,only intermediate coated. Finish coating shall be field applied and colorcoded when installed.

Colors - Primer to be manufacturer's standard color. Finish coat of hydrantbody shall be blue (Acro 555 crystal blue or equivalent). The hoseconnection caps shall be finish coated white, and a white band of finishcoat 50 millimeters in width shall be painted on the hydrant bodyapproximately 150 millimeters above the traffic flange and parallelthereto. Intermediate coat shall be of a contrasting color to the blue finishcoat, such as white.

33-75 50932-97

(ii) Exterior Below Traffic Flange. Surface preparation shall be inaccordance with SSPC-SP10 (NACE 2), near-white blast cleaned surface.

Coat with a three (3) coat system as follows:

Primer and intermediate coat-coal tar epoxy, Acro Products No. 4467, orapproved equal, shall be in general conformance with SSPC PaintSpecification No. 16. Apply two (2) coats with a dry film thickness (DFT)of 200-250 micrometers each for a total dry film thickness (DFT) of 400-500 micrometers.

Finish coat - water based vinyl acrylic mastic, Acro Products No. 7782, orapproved equal. Apply one (1) coat with a dry film thickness (DFT) of150-200 micrometers. Color of finish coat shall be the same as the finishcoat for the exterior above the traffic flange i.e., blue (Acro 555 crystalblue or equivalent)

(iii) Interior Surfaces Above and Below Main Valve. All material used forinternal coating of hydrant interior ferrous surfaces below the main valvemust be NSF61 listed as suitable for contact with potable water as requiredby Chapter 290, "Rules and Regulations for Public Water Systems," TexasNatural Resources Conservation Commission (TNRCC).

Surface preparation shall be in accordance with SSPC- SP10 (NACE 2),near - white blast cleaned surface.

Coating shall be liquid or powder epoxy system and be in accordance withAWWA Standard C-550. Coating may be applied in two (2) or three (3)coats, according to manufacturer's recommendations, for a total dry filmthickness of 300-450 micrometers.

(iv) General. All coatings shall be applied in strict accordance withmanufacturer's recommendation. No requirement of this specificationshall cancel or supersede the written directions and recommendations ofthe specific coating manufacturer so as to jeopardize the integrity of theapplied system.

The hydrant supplier shall furnish an affidavit of compliance that allmaterials and work furnished comply with the requirements of thisspecification and applicable standards referenced herein.

After all hydrants have been installed and prior to the main beingaccepted, the Contractor shall paint the bonnet portion of each fire hydrantas follows:

34-75 50932-97

Size of Supply Line,Millimeters Color of Bonnet

150 Yellow200 White

250-500 Green600 and larger Orange

The color shades and paint quality shall comply with the currentspecifications and is subject to the approval of the Engineer.

(g) Performance Standards

(i) Provide hydrants capable of a free discharge of 5678 liters per minute orgreater from single pumper nozzle at a hydrant inlet static pressure notexceeding 138 kilopascals as measured at or corrected to hydrant inlet atits centerline elevation.

(ii) Provide hydrants capable of a discharge of 5678 liters per minute orgreater from single pumper nozzle at a maximum permissible head loss of55 kilopascals (when corrected for inlet and outlet velocity head) for aninlet operating pressure not exceeding 255 kilopascals as measured at orcorrected to hydrant inlet at its centerline elevation.

Hydraulic Performance Testing: AWWA C502; certified pressure lossand quantity of flow test shall be conducted by qualified testing laboratoryon production model (1.5 meter bury length) of hydrant (same catalognumber) proposed for certification. Submit certified test report containingfollowing information:

1) Date of test, no more than five (5) years prior, on fire hydrant withsimilar hydraulic characteristics.

2) Name, catalog number, place of manufacture, and date of productionof hydrant(s) tested.

3) Schematic drawing of testing apparatus, containing dimensions ofpiping elements including:

a) Diameter and length of inlet piping.

b) Distance from flow measuring points to pressure measurementpoint.

c) Distance from flow and pressure monitoring points to hydrantinlet.

d) Distance from pressure monitoring point to nozzles.

e) Diameter and length of discharge tubing.

4) Elevation of points of measurement, inlet, and outlet.

35-75 50932-97

5) Reports, or certificates documenting accuracy of measuring devicesused in test.

Conduct test on at least three (3) hydrants of the same fabrication design.Inlet water temperature: 21 degrees Celsius plus or minus 2.5 degreesCelsius.

For Traffic Impact Testing submit a certified test report which outlinesresults of traffic impact test involving standard production models of firehydrant with breakable barrels same in design to that proposed forcertification. Install these hydrants per AWWA C600; strike at a point450 millimeters plus or minus 50 millimeters above designated groundline.

Point of impact on hydrant barrel shall be within 50 millimeters of lineperpendicular to base and equidistant from pumper nozzle and one hosenozzle. Conduct successive tests simulating impacts by standardAmerican-made vehicles with gross weights of 1588, 2495 and 4763kilograms.

Document tests to provide the following minimum information:

a) Detailed schematic drawing(s) of test facility.

b) Complete description of mechanical impact testing equipment used.

c) Complete list of hydrant parts and materials damaged in each impacttest.

d) Photographs.

e) Size and static pressure of line to which hydrant is attached.

f) Estimate of amount of water discharged, if any, from hydrant withinthirty minutes immediately following collision.

(h) Hydrant Lead. Provide hydrant branch leads conforming to the samerequirements under Subarticles 2.(2), 2.(3), 2.(4), or 2.(5) of this specification.

(14) Polyethylene Film Wrap.

(a) General. Except where noted on the plans, polyethylene film shall be used as awrap to protect cast-iron pipe, ductile-iron pipe and fittings. Polyethylene filmshall conform to the requirements outlined herein and shall only be used in open-cut construction.

(b) Film. The polyethylene film shall be in accordance with ASTM 1248 and AWWAC105, Type 1, Class C, Category 5, Grade J-3, 2.5 to 3 percent carbon blackcontent. Unless otherwise specified on the plans, the film shall be 200 micrometersthick and minimum tensile strength of 8.3 to 17.2 megapascals with elongation upto 600 percent. It may be furnished either in tubular form or in sheet form. Film intubular form shall be furnished in the following minimum widths:

36-75 50932-97

Minimum Width of Film Tube (when laying flat)

NominalPipe Size,

Millimeters

Push-on JointFlat Tube Width,

Millimeters

100 350150 425200 525250 625300 725350 825400 925450 1025500 1125600 1325

Film in sheet form shall have a width equal to twice that shown for tube widths.

(c) Polyethylene Tape. The tape used to tape film edges and overlaps shall be 75millimeter wide plastic backed adhesive tape. The tape shall be Polyken No. 900,Scotch Wrap No. 50 or approved equal.

(15) Bedding Material. Unless otherwise specified on the plans bedding for water mainsshall be one of the following:

(a) Bank Run Sand. Bank run sand may be used for bedding as called for in thesespecifications and shall consist of soil classified as SP, SW or SM by the UnifiedSoil Classification System (USCS). The sand shall have a plasticity index, whentested, of less than seven (7) percent and shall have a liquid limit of 25 or less.Bank run sand shall have no more than 15 percent passing the 0.075 millimetersieve when tested. The material shall be free of any roots, organic material, trash,clay lumps or other deleterious or other objectionable material.

(b) Concrete Sand. Concrete sand may be used as bedding material for water mainsand shall conform to the specifications for Fine Aggregate specified in ASTMStandard C-33. Fine Aggregate shall consist of natural sand, manufactured sand ora combination thereof and shall be graded within the following limits.

Sieve Size,Millimeters Percent Passing

9.50 1004.75 95-1002.36 80-1001.18 50-850.60 25-600.30 10-300.15 2-10

The aggregates shall not consist of any roots, organic material, trash, clay lumps orother deleterious or other objectionable materials, in excess of limits prescribed inthe C-33 Standard.

37-75 50932-97

(c) Pea Gravel. Pea Gravel may be used as bedding material for water mains and shallconform to the specifications for Coarse Aggregates specified for the 2.36millimeter size in ASTM Standard C-33. Coarse Aggregates shall consist of gravelcomposed of small, smooth, rounded stones or pebbles and shall be graded withinthe following limits.

Sieve Size,Millimeters Percent Passing

12.50 1009.50 85-1004.75 10-302.36 0-101.18 0-5

The aggregates shall not consist of any roots, organic material, trash, clay lumps orother deleterious or other objectionable materials, in excess of limits prescribed inthe C-33 Standard.

(d) Gem Sand. Gem sand may be used as bedding material for water mains and shallgenerally conform to specifications for Coarse Aggregates specified for 2.36millimeter size in ASTM Standard C-33. Specifically, the aggregates shall begraded within the following limits.

Sieve Size,Millimeters Percent Passing

9.50 95-1006.35 60-804.75 15-402.00 0-5

The aggregates shall not consist of any roots, organic material, trash, clay lumps orother deleterious or other objectionable materials in excess of limits prescribed inthe C-33 Standard.

(16) Backfill Material. Unless otherwise specified on the plans, sand for backfillencasement of water mains shall be one of the following materials:

(a) Cement Stabilized Sand. Cement stabilized backfill shall contain a minimum offive (5) percent Portland cement per cubic meter of material as placed based on thedry weight of the aggregate in accordance with Test Method Tex-120-E. Thematerials shall consist of aggregate, Portland cement, and water. Cement and watershall conform to the material requirements of Item 421, "Portland CementConcrete". Aggregate shall be sand, free from deleterious matter, with a plasticityindex not greater than six (6) when tested by Test Method Tex-106-E.

(b) Earth or Native Soil. Earth or native soil backfill shall consist of soil containingno deleterious material to include trash, wood fragments, organics, or otherobjectionable material. The material may be from either the material removed fromthe excavation or offsite sources. The material may consist of soil classified by theUnified Soil Classification System (USCS) as ML, CH, CL, CL-ML, SC, SP, SM,

38-75 50932-97

SW or GC. Earth Backfill proposed to be used shall meet the compactionrequirements specified herein and shall not cause any settlement.

(c) Bank Run Sand. Bank Run Sand may be used for backfill as called for in thesespecifications and shall conform to the same requirements under Section 2.(15)(a),"Bank Run Sand".

(17) Concrete. All concrete shall be Class "A" conforming to the requirements of Item 421,"Portland Cement Concrete", unless otherwise specified on the plans.

All forms shall be left in place unless the Engineer directs that certain sections of theforms be removed.

(18) Grout for Prestressed Concrete Cylinder Pipe Joints.

(a) General. Water shall have total dissolved solids less than 1000 milligrams per literas measured in accordance with ASTM D 1888, Method A; chloride ions less than100 milligrams per liter for slurry and mortar cure, as measured in accordance withASTM D 512; pH greater than 6.5 as measured in accordance with ASTM D1293.

(b) Cement Grout Mixture. Provide cement grout consisting of one (1) part cement,conforming to ASTM C150-Type II, and two (2) parts of fine graded plaster sand,conforming to ASTM C35.

Interior joint grout shall be mixed with as little water as possible so that the groutwill be very stiff but workable.

It shall be capable of being placed with a plastic consistency in the interior pipejoint.

(c) Nonshrink Grout. The nonshrink grout shall meet the following requirements:

It shall be a pre-blended factory packaged material manufactured under rigidquality control, suitable for use in the joints of prestressed concrete cylinder pipe.

It shall contain nonmetallic natural aggregate and shall be nonstaining andnoncorrosive.

It shall conform to the requirements of the Corps of Engineers' Nonshrink GroutSpecification CRD C-621, and ASTM C1107, when tested at fluid consistency.

It shall be suitable for use in contact with potable water supply.

It shall be highly flowable so that the joint wrapper around the exterior pipe jointcan be filled without leaving any voids or trapped air.

It shall be nonbleeding and nonsegregating at a fluid consistency.

It shall not contain any chlorides or additives which may contribute to corrosion ofthe steel material.

It shall be free of gas-producing or gas-releasing agents.

39-75 50932-97

It shall resist attack by oil and water.

"EUCON N-S Grout" as manufactured by Euclid Chemical Company, Cleveland,Ohio, "Gilco Construction Grout" as manufactured by Cormix ConstructionChemicals, Dallas, Tx. or approved equal shall be considered acceptable.

The nonshrink grout shall be mixed, placed and cured in accordance with themanufacturer's instructions and recommendations.

The manufacturer of the nonshrink grout shall make available, at no additional cost,and upon 72 hours notice, the services of a qualified representative to aid theContractor in assuring proper use of the product under job conditions and shall beon site when the product is first used.

The grout shall have a minimum 7-day unconfined compressive strength of 17.2megapascals, and a minimum 28-day unconfined compressive strength of 34.4megapascals. Strength shall be tested in accordance with ASTM C1107.

Joint wrappers shall have minimum width of 225 millimeters for 825 millimeterdiameter pipe and 300 millimeters for larger diameter pipe. The wrapper shall behemmed at each edge to allow threading with a minimum 16 millimeter wide steelstrap. Wrappers shall have a minimum 100 millimeter wide ethafoam strip sewncircumferentially in the center of the 300 millimeter wrapper and a 150 millimetersstrip in the 225 millimeter wrapper to resist backfill penetration into the exteriorjoint recess.

All forms shall be left in place unless the Engineer directs that certain sections ofthe forms be removed.

(19) Water Meters, Meter Vaults and Meter Boxes.

(a) Water Meters. Provide meters of the type and size as indicated on the plans.

(i) Provide bolted split casings. Main casings of meters and externalfasteners: Copper alloy with minimum 75 percent copper for 16 millimeterto 50 millimeter, bronze or cast-iron, hot-dipped galvanized or epoxycoating for coating for 75 millimeters and larger.

(ii) Straightening Vanes: Noncorrosive material compatible with casematerial.

(iii) Intermediate gear train not to come in contact with water; operate insuitable lubricant.

(iv) Register: Standard; permanently sealed; straight-reading; center-sweeptest hand; magnetic driven; reading in liters ; adaptable to remote read.Digits: 6, black in color with lowest registering three digits (below 1000liter registration) having contrasting digit and background color. Registercapacity of meters: 99,999 kiloliters for 16 to 50 millimeter sizes and9,999,999 kiloliters for sizes 75 millimeters and larger.

40-75 50932-97

(v) Connections: 16 to 25 millimeters: Thread at each end; 38 to 50millimeters: Two-bolt oval flanges each end; 75 millimeters and larger:Flange at each end.

(vi) Register Boxes: Glass: High-impact strength tempered, encased in highcontent copper or stainless steel housing; rings and covers; copper alloywith minimum 57 percent copper.

(vii)Stamp manufacturer's meter serial number on outer case and on outside ofregister lid. Manufacturer's serial numbers shall be individual and notduplicated.

(viii)Meters: Be adaptable to direct-reading, remote registers or electronicmeter reading technology. Compound Meter manufactured by: HerseyProducts, Neptune, Sensus or equal. Turbine or Fire Service Metermanufactured by: Badger, Hersey Products, Neptune, Sensus or equal.Displacement meter: Badger, Neptune, Sensus or equal.

(ix) Manufacturing Quality Control: Permit successful interchangeability fromone meter to another of same size; registers, measuring chambers andunits, discs or pistons as units, change gears, bolts, nuts, and washerswithout affecting herein specified accuracy of new meter.

(x) Commercial Meter Valves for Meter Installations. Commercial metervalves shall be identical with line valves except that they shall have Class125 flanges, and be equipped with handwheels operating counterclockwiseto open.

All pipe and fittings inside the meter box or meter vault shall be ductile-iron or cast-iron conforming with Subarticles 2.(3), "Ductile-Iron Pipe andFittings" and 2.(4), "Cast-Iron Pipe and Fittings", of this specification andas specified on the plans.

(b) Meter Vault.

(i) General. Meter vaults may be furnished in either of the followingdesigns: precast concrete vault, cast-in-place concrete vault or solidmasonry, unless specific type of construction is required on plans. Allconcrete shall be Class "S" conforming to the requirements of Item 421,"Portland Cement Concrete".

(ii) Precast Concrete Vault. Precast concrete vault shall be constructed asshown on the plans. All reinforcing steel shall conform to therequirements of Item 440, "Reinforcing Steel".

Install precast vaults in accordance with the manufacturersrecommendations. Set level on a minimum 75 millimeter thick bed ofsand conforming to the requirements of Subarticle 2.(15), "Backfill", ofthis specification. Lifting holes shall be sealed with cement mortar ornon-shrink grout.

41-75 50932-97

(iii) Meter Vault Floor Slab:

1. Construct floor slabs of 150 millimeter reinforced concrete. Slopefloor at two (2) percent grade toward sump. Make sump 300millimeters in diameter, or 300 millimeters square, and 100millimeters deep, unless other dimensions are shown on the plans.Install dowels at maximum of 450 millimeters, center-to- center, orinstall mortar trench for keying walls to floor slab.

2. Precast floor slab elements may be used for precast vault construction.

(iv) Cast-In-Place Concrete Vault. Cast-in-place concrete vaults shall beconstructed as shown on the plans. All reinforcing steel shall conform tothe requirements of Item 440, "Reinforcing Steel". Key walls to the floorslab. The minimum wall thickness shall be 100 millimeters. Walls shallbe cast monolithically unless vault depth exceeds 3.6 meters. If vaultdepth is 3.6 meters or greater, one (1) cold joint shall be allowed.

(v) Frame and Cover. All welded steel shall be A-36 or equal. Cover plateshall be a 6.35 millimeter skid resistant raised pattern floor plate. Meteraccess door shall be made from the same material as cover plate. Allwelding shall be accomplished in accordance with the provisions of Item441, "Steel Structures". Nondestructive testing will not be required.

Castings for frames, grates, rings and covers shall conform to ASTM A48Class 30. Provide locking covers if indicated on the plans. Castings shallbe capable of with standing the application of an AASHTO HS-20loading, unless otherwise specified.

Covers and frames shall conform to the shapes dimensions, and beprovided with the wording or logos shown on the plans. Standarddimension for all manhole covers shall be 800 millimeters. Frames, grates,rings and covers shall conform to Item 471 "Frames, Grates Rings andCovers" except as noted above and except for measurement and payment.

(c) Meter Box.

(i) General. Meter boxes for 16 millimeter through 25 millimeter watermeters shall be of the following materials:

a) Non-traffic bearing locations shall be Cast-Iron, concrete or plastic asspecified on the plans.

b) Traffic bearing location: Cast-Iron, Meter boxes for 38 and 50millimeter water meters shall be cast iron at all locations.

Meter box lids shall have key-operated, spring type, locking device andshall have a reading lid. Lids shall contain sufficient metals that meterbox can be easily located with metal detector. If words are specified onthe plans, they shall be cast into lid with letters of 50 millimeters height

42-75 50932-97

and raised by 2 millimeters. Size shall read 16 to 25 millimeter or 38 to50 millimeter.

Meter box dimensions shall conform to the following approximatedimensions.

a) Length: At top 390 millimeters; at bottom 500 millimeters

b) Width: At top 315 millimeters; at bottom 375 millimeters

c) Height: 300 millimeters

Meter box extensions 75 millimeters and 150 millimeters in height shallbe available from the manufacturer.

(ii) Cast-Iron Meter Boxes. Cast-iron boxes shall be clean and free fromsand blow-holes or other defects and shall conform to the requirements ofASTM A48. Bearing surfaces shall be machined so that covers seat evenlyin frames. Boxes and lids shall have dipped, coal-tar-pitch, varnish finish.Provide lock-type meter boxes when shown on the plans. Lockmechanisms shall work with ease.

(iii) Concrete Meter Boxes. Concrete meter boxes shall be made of Class"A" concrete conforming to requirements of Item 421 "Portland CementConcrete". Construct boxes as shown on the plans. Castings shall be freefrom fractures, large or deep cracks, blisters or surface roughness or anyother defects that may affect serviceability.

(iv) Plastic Meter Boxes. Plastic meter boxes shall be made of high densitypolyethylene conforming to the following ASTM Specifications:

ASTM Requirement

D256 Impact Strength = 0.101 N-m/mm(Izod, Notched)

D256 Impact Strength = 0.34 N-m/mm(Izod, Un-Notched)

D638 Tensile Strength (2.0 Min) = 23megapascals

D648 Deflection Temperature = 76.5 CelsiusD790 Flexural Modulus = 620 megapascalsD676 Shore D Hardness, 55-65 Impact

Strength, Falling Dart Method,11.3 Newton-meters

Meter boxes shall meet the following test requirements:

1) Static Load: Not less than 1134 kilograms using 150 millimeter discwith direct compression exerted at center of top of meter box withsolid plastic lid.

2) Deflection: Not less than a 4448 Newton load required to deflect topedge of meter box 3 millimeters.

43-75 50932-97

Meter box body, without lid, shall weigh approximately 3 kilograms.

(20) Affidavit of Compliance. Unless otherwise directed by the Engineer, the Contractorwill be required to furnish a manufacturer's affidavit of compliance for each of thematerials used in this project. The affidavit shall certify that factory inspection and allspecified tests have been made and that the material furnished complies with therequirements outlined herein.

(21) Pressure Reducing Station. All station piping, valves and fittings shall be new andunused unless otherwise specified on the plans and shall be of the same type asspecified on the plans.

Concrete shall be Class "S" conforming to Item 421, "Portland Cement Concrete".

Reinforcing steel shall conform to Item 440, "Reinforcing Steel".

A pressure reducing valve (PRV) with strainer shall be provided in the location andarrangement as shown on the plans. The valve body shall be ASTM A 48 cast iron orASTM A 126, Class B cast iron with 125 Class ANSI B16.1 flanges. The valve covershall be ASTM A 48 cast iron. All valve internals shall be Type 303 stainless steel orB-62 bronze. All rubber parts shall be Buna-N. No leather parts shall be allowed.Resilient seat shall have a rectangular cross section.

Control tubing shall contain shutoff cocks with a "Y" strainer. The valve shall beequipped with a valve position indicator.

The valve and valve box shall be initially set in the field by an authorizedmanufacturer's representative. The downstream pressure shall be set at 413 kilopascals.The PRV shall come with an adjustable and pressure sustaining pilot systems. Themain valve shall be a diaphragm type valve or piston type valve.

A Cla-Val Model 90-01, or approved equal shall be provided for PRV's 400 millimetersand smaller. Cla-Val Model 690-01 or approved equal for 500 millimeter and 600millimeter PRV's.

A basket strainer upstream of the pressure reducing valve shall be provided as shown onthe plans. Strainer body shall be quick-opening type, fabricated steel construction withANSI Class 150 flanges. The basket shall be Type 304 stainless steel.

A Hayward Model 90 or equal shall be used for PRV's 100 millimeters to 600millimeters and shall be provided. When there are space constraints, A Hayward Model510 or equal for PRV's 350 millimeters or greater, shall be provided.

3. Construction Methods.

(1) Excavation.

(a) Trenches. All water lines shall be constructed in open cut trenches with verticalsides except in those locations where the pipe is to be tunneled, cased or augered.The trench shall conform to the dimensions shown in the excavation and backfilldiagram.

44-75 50932-97

Trenches shall be sheathed and braced to the extent necessary to maintain the sidesof the trench in a vertical position throughout the construction period. Excavationgreater than 1.5 meters in depth shall be protected as specified by Item 402,"Trench Excavation Protection" or Item 403 "Temporary Special Shoring".

The trench must be opened and excavated to the finished grade. Water mains, towhich the mains under construction are to be connected, must be definitely locatedwell in advance of such connection to allow for possible adjustment of alignmentand/or grade.

Water mains shall be constructed in dry trenches. If it becomes necessary toemploy well pointing or additional sheathing to accomplish this objective, thisadditional work shall be performed by the Contractor without additionalcompensation.

For pipes under 500 millimeters in diameter, the minimum trench width below thetop of pipe shall be the outside diameter of the pipe plus 300 millimeters. For pipes500 millimeters and larger, the trench width below the top of pipe shall be not lessthan the outside diameter of the pipe plus 450 millimeters, but not wider than theoutside diameter of the pipe plus 600 millimeters. Additional width will berequired for unstable conditions. Unstable conditions will be determined by theEngineer.

Where it is necessary to excavate trenches adjacent to improved property, theContractor will be required to take necessary precautions so as not to damage orimpair that property. Where it is necessary to disturb grass, shrubs, driveways, etc.,the Contractor will be required to restore such improvements to their originalcondition.

Use sufficient trench width or benches above the embedment zone for installationof well point headers or manifolds and pumps where depth of trench makes ituneconomical or impractical to pump from the surface elevation. Provide sufficientspace between shoring cross braces to permit equipment operations and handling offorms, pipe, embedment and backfill, and other materials.

Before moving supports, place and compact embedment to sufficient depths toprovide protection of pipe and stability of trench walls. As supports are moved,finish placing and compacting embedment.

Immediately prior to placement of embedment materials, the bottoms and sidewallsof trenches shall be free of loose, sloughing, caving, or otherwise unsuitable soil.

Perform placement and compaction directly against the undisturbed soils in thetrench sidewalls, or against sheeting which is to remain in place.

Do not place trench shields or shoring within height of the embedment zone unlessmeans to maintain the density of compacted embedment material are used. Ifmoveable supports are used in embedment zone, lift the supports incrementally toallow placement and compaction of the material against undisturbed soil.

45-75 50932-97

Place haunching material around the pipe and compact it to provide uniformbearing and side support.

Place trench dams in Class I embedments near the midpoint of line segments longerthan 30 meters between manholes.

Where damage to completed pipe installation work is likely to result fromwithdrawal of sheeting, leave the sheeting in place.

(b) Existing Streets. Unless otherwise shown on the plans, all existing streets shall beopen cut.

Where water line construction necessitates cutting through existing streets outsidethe limits of new street construction, said streets shall be replaced in kind inaccordance with the appropriate specifications in the proposal or as directed by theEngineer.

Where, in the opinion of the Engineer, it is necessary to maintain traffic across atrench, the Contractor will be required to construct temporary bridges as necessaryto facilitate the movement of traffic.

At locations where the proposed water main parallels the edge of an existingpermanent pavement (i.e., concrete pavement, concrete base with asphalt surface,etc.), and is one (1) meter or less from the edge of that pavement, the trench shallbe protected with timber sheathing and bracing. Bracing shall be left in place atintervals not to exceed 1.5 meters.

The street surface adjacent to the trench must be kept free of surplus spoil.Construction materials shall be placed at locations that will minimize interferencewith the traveling public.

No more than two (2) street intersections shall be closed at any one time unlessauthorized by the Engineer in writing.

(2) Jacking, Tunneling or Augering.

(a) General. Jacking, tunneling or augering for water mains shall be performed at thelocations shown on the plans and at such other locations specifically designated bythe Engineer.

Unless otherwise shown on the plans, casing pipe shall conform to the requirementsof Section 2.(2)(b), "Steel Casing Pipe", of this specification.

All auger pits shall be excavated to a finished grade at least 150 millimeters lowerthan that indicated by the construction stakes or as approved by the Engineer toensure that a dry bottom is encountered.

The minimum width of jacking, tunneling or augering pits shall be such that thereshall be at least 150 millimeters of space between the pipe and the walls of theauger pit. The maximum allowable width of the pit shall be 1.5 meters unlessapproved by the Engineer. The width of the pit at the surface shall not be less than

46-75 50932-97

at the bottom. The maximum allowable length of the pit shall be not more than 1.5meters longer than one (1) full joint of pipe of the type being used and shall notexceed 7.5 meters unless approved by the Engineer.

There must be no inadvertent metallic contact between casing and carrier pipe.Spacing of spacers should ensure that carrier pipe is adequately supportedthroughout its length, particularly at ends, to offset settling and possible electricalshorting. End spacer must be within 150 millimeters of end of casing pipe,regardless of size of casing and carrier pipe or type of spacer used. Casing spacersare designed to withstand much greater loads than can be safely applied to mostcoatings. Therefore, spacing between spacers depends largely on load bearingcapabilities of pipe coating and flexibility of pipe.

Casing spacers should be installed in accordance with manufacturer's instructions.Special care should be taken to ensure that all subcomponents are correctlyassembled and evenly tightened, and that no damage occurs during tightening ofinsulators or carrier pipe insertion.

Annulus between carrier pipe and casing should be sealed with casing end seals ateach end of casing.

Insulator Spacing:

1) Spacing shall be as shown on the plans with the maximum distance betweenspacers to be 3 meters for pipe sizes 100 to 350 millimeters and 2.5 meters forpipe sizes 400 to 750 millimeters.

2) For ductile iron pipe, flanged pipe, or bell-and-spigot pipe, spacers should beinstalled within 300 millimeters on each side of the bell or flange and one inthe center of the joint when 5.5 to 6 meter-long joints are used.

3) If casing or carrier pipe is angled or bent, spacing should be reduced.

Bedding and backfill of jacking, tunneling, boring or augering pits shall be inaccordance with details on the plans and these specifications.

(b) Jacking of Steel Casing. Jacking of steel casing shall conform to the requirementsof Item 476, "Jacking, Boring or Tunneling Pipe".

(c) Tunneling. Tunneling shall conform to the requirements of Item 476, "Jacking,Boring or Tunneling Pipe".

(d) Augering. Boring or augering shall conform to the requirements of Item 476,"Jacking, Boring or Tunneling Pipe".

Do not exceed 30 meters for length of auger hole without an intermediate pit.

Do not exceed 23 meters for length of auger hole for PVC pipe 300 millimeters andless in diameter without an intermediate pit.

Do not exceed 12 meters for length of auger hole for PVC pipe 400 millimeters andgreater in diameter without an intermediate pit.

47-75 50932-97

At all locations where water pipes cross underneath driveways (of 4.88 meters orless in width) and/or sidewalks, pipe shall be installed in tight fitting augered holes.

At locations where the centerline of the proposed water main is three (3) meters orless from the centerline of a growing tree, 200 millimeters in diameter or larger, thepipe shall be placed in a tight fitting augered hole. The bored hole shall extend atleast 1.2 meters beyond each side of the tree.

The void space around the pipe in the augered hole shall be blocked withapproximately 300 millimeters of packed clay or similar material approved by theEngineer, in such a manner that the bedding or backfill does not escape into thevoid around the pipe in the auger hole when compacted. The minimum volume ofthe clay or similar acceptable material to be used around the pipe shall be asfollows:

Pipe Diameter,Millimeters Minimum Quantity

100 through 200 0.014 cubic meters300 through 400 0.021 cubic meters

(e) Bedding for Trenches, Jacking, Tunneling, Boring or Augering Pits.

(i) Pipe Bedding for Water Mains less than 750 millimeters in Diameter.

1) Open Cut Installation. All trenches shall have a minimum of 150millimeters bedding.

The soil in the bottom of the trench, excavated to a depth of 150millimeters below the bottom of pipe, shall be removed and replaced withbedding material. All saturated material from the bottom of the pit shallbe removed prior to placing the bedding. The pipe shall be placed in thebedding such that there is a 150 millimeter bedding below and up to thespring line of the pipe. All bedding material shall be compacted tostandard density within five (5) percent of optimum moisture asdetermined by Test Method Tex-113-E. All bedding material shall bemechanically compacted by using vibratory equipment or any otherequipment acceptable to the Engineer.

2) Auger Pits. All auger pits shall have a minimum of 150 millimeterbedding. The soil in the pit, excavated to a minimum depth of 150millimeters below the bottom of pipe shall be removed and replaced withbedding material.

All saturated material from the bottom of the pit shall be removed, prior toplacing the bedding material. The pipe shall be placed in the bedding suchthat there is a 150 millimeter bedding below and up to the spring line ofthe pipe.

All bedding material shall be mechanically compacted by using vibratoryequipment or any other equipment acceptable to the Engineer. All

48-75 50932-97

bedding material shall be compacted to 90 percent of the standard densitywithin five (5) percent of optimum moisture, as determined by TestMethod Tex-113-E.

3) The following are the acceptable materials for bedding as described inSubarticle 2.(15), "Bedding Material", of this specification:

a) Pea Gravel; b) Concrete Sand; c) Gem Sand.

Bank run sand may be used as bedding material around the pipe only if, inthe opinion of the Engineer, the trench bottom and sides are dry. If sand isused, the pipe shall be placed in the bedding such that there is at least a150 millimeter bedding around and on top of the pipe. Sand shall becompacted as described in (1) above.

(ii) Pipe Bedding for Large Diameter Water Mains (30 Inches or Greater inDiameter).

Open Cut. The soils in the bottom of the trench shall be excavated 150millimeters below the specified bottom of pipe for either concrete, ductile ironpipe, or steel waterlines. The 150 millimeter space shall be backfilled withbank run sand and compacted to 90 percent of the standard maximum densitywithin five (5) percent of optimum moisture, as determined by Test MethodTex-113-E.

If the bottom of the excavation becomes wet due to the presence ofgroundwater and a dewatering system is not required, and if directed by theEngineer, the Contractor shall over-excavate an additional 150 millimeters to adepth of 300 millimeters below the bottom of the pipe. The Contractor shallplace a non-woven geotextile fabric and then compact 300 millimeters of bankrun sand or concrete sand in one (1) lift on top of the fabric. The upper 150millimeters shall be compacted to 90 percent of the standard maximum densityas determined by Test Method Tex-113-E. The Engineer may require removalof unstable or unsuitable material by the Contractor, even though theContractor has not determined the material to be unsuitable.

Cement stabilized sand utilized as backfill or as pipe bedding as specified onthe plans shall be compacted in 150 millimeter lifts to 90 percent of thestandard maximum density as determined by Test Method Tex-113-E, atoptimum moisture content.

(3) Handling of Pipe and Accessories. At all times during pipe construction operations,the Contractor shall use every precaution to prevent injury to the pipe, protective liningsand coatings in accordance with manufacturer's recommendations. The Contractor shallnot place debris, tools, or other materials in the pipe.

Any damage to the pipe or the protective lining and coating from any cause during theinstallation of the pipeline and before final acceptance by the purchaser shall berepaired at the expense of the laying contractor as directed by the Engineer and inaccordance with the applicable standards.

49-75 50932-97

Pipe, fittings, valves and accessories shall be unloaded at the point of delivery andhauled to the site of the project. The material shall be distributed opposite or near theplace where it is to be laid in the trench such that storm water or runoff will not enter orpass through the pipe. Under no circumstances shall the materials be dropped. Pipehandled on skidways shall not be skidded or rolled against pipe already on the ground.

All pipe and fittings shall be loaded, transported, unloaded and otherwise handled in amanner and by methods which will prevent damage of any kind thereto. Pipe shall behandled and transported with equipment designed, constructed and arranged to preventdamage to the pipe, lining and coating. Bare chains, hooks, metal bars, or narrow skidsor cradles will not be permitted to come in contact with the coatings. Provide pipefittings with sufficient interior strutting or cross-bracing to prevent deflection undertheir own weight.

Pipe and fittings shall be hoisted from the trench side into the trench by means of a slingof smooth steel cable, canvas, leather, nylon or similar material. Pipe shall not be liftedusing hooks at each end of the pipe. When pipe is stacked, pipe is to be packaged ontimbers. Protective pads are to be placed under banding straps at the time of packaging.

When fork trucks are used to relocate pipe, the forks shall be padded using carpet orsome other suitable type of materials. When pipe is relocated using a crane or backhoe,nylon straps or smooth steel cable and not chains shall be used around the pipe for lift.

(4) Pipe Cutting. Cast-iron and ductile-iron pipe, 300 millimeters in diameter and smaller,shall be cut in accordance with the manufacturers recommendations. All pipe largerthan 300 millimeters shall be cut in a manner approved by the Engineer. Each cut shallbe at right angles to the axis of the pipe and shall be filed or grind to remove sharpedges.

(5) Defective or Damaged Material. Pipe and accessories shall be inspected for defectsprior to being lowered into the trench. Any defective, damaged, or unsound materialshall be repaired or replaced as directed by the Engineer.

Should a damaged piece of pipe furnished by the Contractor be placed in the watermain, the Contractor shall furnish at his expense all labor and materials required forremoving and replacing the defective pipe and restoring the street to its originalcondition. Should the Contractor damage the pipe after installation, the Engineer maypermit the damaged section to be cut from the length unless it is the opinion of theEngineer that the entire length was damaged. The cost and replacement of broken pipewill be at the expense of the Contractor.

(6) Cleaning of Pipe and Accessories. All lumps, blisters and excess coating shall beremoved from the bell and spigot ends of cast-iron pipe, ductile-iron pipe, valves,hydrants and fittings. The outside of the spigot and the inside of the bell shall be wirebrushed and wiped clean, dry and free from oil and grease before the pipe is laid.

All foreign matter or dirt shall be removed from the interior of all water pipe andaccessories and from the mating surfaces of the joints prior to lowering the material intothe trench. The pipe and accessories shall be kept clean during and after laying bymeans approved by the Engineer.

50-75 50932-97

Cleaning solutions, detergents, solvents, etc. should be used with caution when cleaningPVC pipe.

(7) Laying of Pipe. For the work of laying the pipe, the Contractor shall employ onlyworkers who are skilled and experienced in laying pipe of the type and jointconfiguration being furnished. It shall be the responsibility of the Contractor to providewatertight pipe and pipe joints. Pipe shall be laid with bell ends facing in the directionof laying, unless otherwise directed by the Engineer.

Pipe shall be laid to the lines and grades shown on the plans. To ensure properplacement, the Contractor shall use adequate surveying methods and equipment andshall employ personnel competent in the use of this equipment. The pipe shall notdeviate from the horizontal and vertical alignment as indicated on the plans by morethan 30 millimeters without prior approval of the Engineer. The Contractor shallmeasure and record the "as-built" horizontal alignment and vertical grade at a maximumof every 15 meters on the on-site recorded plans.

Pipe trenches shall be kept free of water which might impair pipe laying operations atall times during laying operations. Holes for bells shall be of ample size to prevent bellsfrom coming in contact with the subgrade. Pipe trenches shall be carefully graded so asto provide uniform support along the bottom of pipe.

Not more than 15 meters of pipe shall be laid in the trench ahead of backfillingoperations and if pipe laying operations are interrupted overnight, all pipe laid in thetrench shall be covered simultaneously on each side of the pipe or backfill completed toavoid lateral displacement of the pipe and damage to the joints. If adjustment of theposition of a length of pipe is required after it has been laid, it shall be removed and re-laid in accordance with these specifications and at the Contractor's expense. After allpipe laying and joining operations are completed, the inside of the pipe shall be cleanedand all debris removed.

Care shall be taken to prevent damage to the coating when placing backfill. Backfillingshall be in accordance with Subarticle 3.(9), "Backfilling", of this specification.

Pipe shall be laid in a straight line unless otherwise shown or approved by the Engineer.Long radius curves, either horizontal or vertical, may be laid with standard pipe bydeflections at the joints. If the pipe is shown curved and no special fittings are needed,the curves can be made by deflection of the joints with standard lengths of pipe asapproved by the Engineer. Maximum pipe joint deflection, if permitted, shall notexceed the pipe manufacturer's recommendation. Gasketed pipe shall be jointed in astraight alignment and then deflected to the curved alignment.

If the deflection exceeds the maximum recommended by the manufacturer, theContractor shall be required to remove the entire portion of the deflected pipe sectionand install new pipe as directed by the Engineer. This work will not be paid for but willbe at the Contractor's entire expense.

Where field conditions require deflection curves not shown on the plans, the Engineerwill determine the methods to be used. No additional payment will be made for laying

51-75 50932-97

pipe on curves as shown, nor for field changes involving standard lengths of pipedeflected at the joints.

Assessment of deflection may be measured by the Engineer at any location along pipe.Arithmetical averages of the deflection or similar average measurement methods willnot be deemed as meeting the intent of the standard.

The pipe, valves, hydrants and fittings shall be adjusted so as to be at their properlocations and each joint shall be prepared as specified in Subarticle 3.(8), "Joining ofPipe and Appurtenances", of this specification. As each joint of pipe is laid in thetrench, the spigot end shall be centered in the bell of the previously laid pipe; the pipeshall be forced home and brought to correct line and grade. Each length of pipe shallrest on the bottom of the trench throughout its entire length.

Whenever the laying of pipe is discontinued for the day or for an indefinite period, acap or plug shall be tightly placed in the end of the last pipe laid to prevent the intrusionof water. When water is excluded from the interior of pipe, enough backfill shall beplaced on the pipe to prevent floating. The Contractor shall schedule his work toprevent the possibility of floatation. Any pipe that has floated shall be removed fromthe trench and relaid as directed by the Engineer.

When PVC pipe has been assembled on top of the trench, it shall be allowed to cool toground temperature before backfilling to prevent pull out due to thermal contraction.

For Prestressed Concrete Cylinder Pipe, the manufacturer shall provide the services of aservice representative for a period of not less than two (2) weeks at the beginning of theactual pipe laying operations to advise the Contractor in all aspects of installationincluding but not limited to handling and storing, cleaning and inspecting, coatings andlinings repairs, and general construction methods as to how they may affect the pipe.

Confirm that separation from gravity sanitary sewers and manholes or from force mainshave minimum clearance as specified herein or 2.75 meters in all directions unless aspecial design is shown on the plans.

(i) Parallel water line and gravity sanitary sewer, force main or manhole withno leaks: Minimum 1.22 meter horizontal clearance from outside wall ofwater line to outside wall of gravity sanitary sewer, force main, ormanhole.

(ii) Water line crossing above a gravity sanitary sewer or force main with noleaks: Minimum 0.61 meter vertical clearance.

(8) Joining of Pipe and Accessories.

(a) Cast-Iron Pipe, Ductile-Iron Pipe, Valves, Hydrants and Fittings. Followingthe thorough cleaning of the inside of the bell and the outside of the spigot,members shall be installed in accordance with the manufacturer's recommendationand AWWA C600 or as modified by these specifications.

52-75 50932-97

Pipe and accessories that are not furnished with a depth mark shall be markedbefore assembly to assure that the spigot end is inserted to the full depth of thejoint.

The fittings on small mains shall be braced with short pieces of 50 millimetergalvanized pipe as directed by the Engineer.

Each cast-iron plug installed under this contract shall be braced by a standard pipeclamp, a 0.9 meter nipple of the same diameter pipe as the nearby sections ofmains, and a block of concrete. Pipe clamps for 100 through 300 millimeter watermains shall be Underwriters approved for underground water service piping. Pipeclamps for water mains 400 millimeters and larger shall conform to details shownon the plans.

Lubrication for rubber-gasketed joints shall be water soluble, non-toxic, non-objectionable in taste and odor imparted to the fluid, non-supporting of bacteriagrowth, and have no deteriorating effect on coatings or the rubber gaskets.

(b) Polyvinyl Chloride Pipe and Accessories. Plastic pipe shall be joined inaccordance with the instructions furnished by the manufacturer. Pipe joined usingsolvent cementing techniques shall not be handled or installed in the trench untilafter the joints are sufficiently "cured" to prevent weakening the joint.

Lubrication for rubber-gasketed joints shall be water soluble, non-toxic, non-objectionable in taste and odor imparted to the fluid, non-supporting of bacteriagrowth, and have no deteriorating effect on PVC or the rubber gaskets.

(c) Welded Joints for Steel Pipe. The joints shall receive a buttweld type doubleweld, in accordance with AWWA C206. Either automatic or hand welders may beused at the Contractor's option. Prior to work being started, the Contractor shallprovide proof of certification of qualification for all welders employed on theproject for all the type of work procedures and positions involved. Qualificationshall be in accordance with AWWA C206.

Complete penetration of deposited metal with base metal shall be assured. Theinside fittings and joints must be free from globules of weld metal which wouldrestrict flow or become loose.

For 900 millimeter diameter and larger pipe, the joints are to be furnished withtrimmed spigots (Carnegie shaped joint only) and interior welded. For 750millimeter diameter and smaller pipe, the joints to be welded are to be exteriorwelded.

Miter end cuts of both ends of butt-welded joints may be used for joint deflectionsof up to 2-1/2 degrees.

All fittings and joints shall be set square and true, and the alignment shall bepreserved during welding operations. The alignment of the butting ends shall besuch as to minimize the offset between surfaces. For pipe of the same nominal wallthickness, the offset shall not exceed 2 millimeters. Line-up clamps shall be used

53-75 50932-97

for this purpose; however, care must be taken to avoid damage to linings andcoatings.

During welding, the lining shall be protected by draping a 450 millimeter wide stripof heat-resistant material over the top half of pipe on each side of lining holdbackto avoid damage to the lining by the hot splatter. The tape coating shall besimilarly protected.

Welding rods shall be of a type compatible with the metal to be welded to obtainthe strongest bond, E-70XX.

The metal shall be deposited in successive layers so that there will be at least two(2) passes or beads for automatic welding and three (3) passes or beads for manualwelding in the completed weld.

On all welds, not more than 6.35 millimeters of metal shall be deposited on eachpass. Each individual pass, including the final one, shall be thoroughly cleaned bywire brushing and/or hammering to remove dirt, slag, or flux.

Welding shall not be performed under any weather condition that would impair thestrength of the weld, such as wet surface, rain or snow, dust or high winds, unlessthe work is properly protected.

Tack welds, if used must be of the same material and made by the same procedureas the completed weld. Otherwise, tack welds shall be removed during weldingoperation.

Dirt, scale and other foreign matter shall be removed from inside piping beforetying in sections, fittings or valves.

The Contractor shall have an independent certified testing laboratory, approved bythe Engineer, to perform weld tests on all portions of the job. The cost of suchtesting shall be included in the contract unit bid price for the water main. Copies ofall test reports shall be furnished to the Engineer for review. Testing shall be madeby X-ray methods for butt welds, for 100 percent of all joint welds. If a defectiveweld is revealed, the cost of the repair and the retesting of the repaired weld will bepaid for by the Contractor. The Engineer shall have the full and final decision as tothe suitability of all welds tested. If any interior or exterior coating or lining isdamaged during the welding process, it shall be repaired and returned to its originalstate as approved by the Engineer in accordance with all applicable AWWAStandards.

(d) Flanged Joints for Steel Pipe. Prior to the installation of bolts, the flange jointsshall be accurately centered and aligned to prevent mechanical prestressing offlanges, pipe and appurtenances. Bolt holes shall be aligned to straddle the vertical,horizontal or north-south center line. The inclination of the flange face from truealignment shall not exceed 1 millimeter in 256 millimeters (or 3.9 millimeters permeter).

Use full-face gaskets for all flanged joints. Provide 3 millimeter thick clothinserted rubber gasket material. Cut gaskets at the factory to proper dimensions.

54-75 50932-97

Use Cadmium plated steel nuts and bolts. Bolts shall be tightened progressively toprevent unbalanced stress. Bolts shall be drawn tight to ensure proper seating ofgaskets.

The Contractor shall pay particular attention to procedures used in tightening andtorquing flanged joints. Improper methods may result in leakage and necessitatecorrective measures. The Contractor should follow recommended industrystandards and guidelines as set forth by the various fabricators and manufacturers.

(e) Rubber Gasketed Bell-and-Spigot Joints For Use On Prestressed ConcreteCylinder Pipe. After the rubber gasket is placed in the spigot groove of the pipe,the rubber gasket cross section shall be equalized by inserting a tool or bar such asa large screwdriver under the rubber gasket and moving it around the periphery ofthe pipe spigot. The gaskets shall be lubricated with a nontoxic water-solublelubricant before the pipe units are jointed. The pipe units shall be fitted together ina manner to avoid twisting or otherwise displacing or damaging the rubber gasket.After the pipe sections are joined, the gaskets shall be checked with a feeler gaugeto ensure that no displacement of the gasket has occurred. If displacement hasoccurred, the pipe section shall be removed and the joint shall be remade as if fornew pipe. Remove the old gasket, inspect for damage and replace if necessarybefore remaking the joint.

(f) Welded Joints For Use On Prestressed Concrete Cylinder Pipe. See therequirements of Section 3.(8)(c), "Welded Joints for Steel Pipe", of thisspecification.

(g) Flanged Joints For Use On Ductile-Iron Pipe and Prestressed ConcreteCylinder Pipe. See the requirements of Section 3.(8)(d), "Flanged Joints for SteelPipe", of this specification.

(h) Joint Grouting For Use On Prestressed Concrete Cylinder Pipe. The groutshall be mixed in a machine mixer except when less than 0.014 cubic meter will beused. Where less than 0.014 cubic meter is required, grout may be hand mixed.Only the amount of grout needed for immediate use shall be mixed. Grout that hasset shall be discarded. Retempering of grout by any means is not permitted.

Grout shall be prepared in small batches so as to prevent stiffening before it is used.Any grout which has become so stiff that proper placement cannot be assured shallbe discarded. Grout for filling grooves shall be of such consistency that it willadhere to the ends of the pipe.

Surface preparation shall involve the removal of all defective concrete, dirt, oil,grease and other foreign material from concrete surfaces by brush, hammering,chipping or other similar means, until a sound, clean concrete surface is achieved.Rust and all foreign materials shall be removed from all metal surfaces that willcontact with the grout.

Refer to Item 420, "Concrete Structures", for special precautions to be used forconcreting during periods of hot or cold weather.

55-75 50932-97

The completion of the outside joint operations and backfilling of the pipe trenchesshall follow pipelaying operations as closely as practical.

Prior to filling the joint with grout, the outside space shall be flushed with water sothat the surfaces of the joint in contact with the grout filling will be thoroughlycleaned and moistened before the grout is poured.

After each joint is fully engaged, a joint grout band consisting of an ethyfoamdiaper material shall be secured around the pipe, over the exterior joint recess insuch a manner that there will be essentially no leakage of grout. There shall be noadditional bedding or backfill material placed on either side of the pipe until afterthe grout band is filled and the grout has mechanically stiffened.

The band shall be completely filled with grout in one (1) operation by filling fromone (1) side only until the grout rises on the opposite side, and then rodded oragitated on both sides of the pipe alternately to settle the grout. The grout shallthen not be agitated for at least 15 minutes to allow excess water to seep throughthe joint band and to allow the grout to mechanically stiffen. After this period,more grout shall be added if necessary to fill the joint completely.

The gap at the top of the joint band shall be protected from backfill by allowing thegrout to stiffen, or by covering with a structurally protective material. The bandshall not be removed from the joint.

For 900 millimeter and larger diameter pipe, once the backfill has been placed andcompacted up to the natural ground surface, pavement or subgrade, the inside jointspace shall be cleaned and the joint surfaces shall be thoroughly wetted beforebeing filled with stiff grout which shall be troweled smooth and flush with theinside surfaces of the pipe.

For 750 millimeter and smaller pipe, prior to backfill being placed and compacted,the inside joint recess shall be filled immediately prior to placing the pipe togetherby "buttering" the bell end with grout. After the joint is engaged, the joint groutshall be finished off smooth and clean as follows:

A swab as approved by the Engineer, shall be used for pipe 500 millimeters andsmaller in diameter.

For the 600 millimeter diameter pipe and larger, joints shall be finished with a handtrowel.

All improperly cured or otherwise defective grout shall be removed and replaced bythe Contractor at the Contractor's expense. The Engineer reserves the right to testthe grout strength at random.

When prestressed concrete cylinder pipe is installed in a tunnel or encasement pipeand clearance within the casing does not permit the outside grout to be placed in thenormal manner, a flexible sealer, such as Flex Protex or approved equal, shall beapplied to the outside of the joint prior to joint engagement. The surfaces receivingthe sealer shall be cleaned and primed in accordance with the manufacturer'srecommendation. Sufficient quantities of sealer shall be applied to assure complete

56-75 50932-97

protection of all steel in the joint area. The interior of the joint shall be filled withgrout as specified after joint closure.

Grouting of the inside joint space for 900 millimeter diameter pipe and larger shallbe accomplished as the joints are engaged. Contractor must obtain writtenacceptance from the Engineer of the inside joints before proceeding with the nextday's pipe laying operation.

(9) Closures and Field Modifications of Prestressed Concrete Cylinder Pipe. Applywelded-wire fabric reinforcement to the interior and exterior of all exposed interior andexterior surfaces greater than 150 millimeters in diameter. Welded-wire fabric:Minimum W1; maximum spacing 50 millimeters by 100 millimeters; 9.5 millimetersfrom surface of steel plate or middle third of lining or coating thickness for mortarthickness less than 19 millimeters.

Fill all exposed interior and exterior surfaces with nonshrink grout.

(10) Thrust Restraint. Provide adequate temporary blocking of fittings when makingconnections to distribution system and during hydrostatic tests. Provide sufficientanchorage and blocking to resist all stresses and forces encountered while tappingexisting waterline. For new water lines 300 millimeters in diameter and larger, restrainjoints as specified in this section. For existing waterlines and waterlines less than 300millimeters in diameter, restrain pipe joints with concrete thrust blocks or provide jointsas specified in this section.

The length of the restrained joints, as shown on the plans, assumes that hydrostatictesting will begin upstream and proceed downstream with respect to the normal flow ofthe water in the pipe. If installation or testing of the pipe differs from this assumption,the Contractor shall submit for approval a revised method of restraining the pipe jointsupstream and/or downstream of the device used to test against (i.e., block valve, blindflange, or dished head plug).

(11) Electrical Continuity Bonds. General: Bond wires shall be attached at the requiredlocations by the thermite welding process.

Thermite Welding Methods: Thermite welding of bond wires to the piping shall beperformed in the following manner:

1) The pipe to which the wires are to be attached shall be clean and dry.

2) Use a grinding wheel to remove coating, mill scale, oxide, grease and dirt from anarea approximately 150 millimeters square. Grind the surface to bright metal.

3) The wires to be thermite welded to the structure shall have approximately 25millimeters of insulation removed from each end, exposing clean, oxide-free copperfor welding.

4) Select the proper size thermite weld mold as recommended by the manufacturer.Placed the wire between the graphite mold and the prepared metal surface. Allwires No. 12 AWG size shall use a copper sleeve crimped over the wire.

57-75 50932-97

5) Place the metal disk in the bottom of the mold.

6) Place the thermite weld charge in the mold. Squeeze the bottom of the cartridge tospread ignition powder over the charge.

7) Close the mold cover and ignite the starting powder with a flint gun.

8) After the exothermic reaction, remove the thermite weld mold and gently strike theweld with a hammer to remove the weld slag. Pull on the wire to assure a secureconnection. If the weld is not secure or the wire breaks, repeat the procedure with anew wire.

9) If the weld is secure, coat bare metal and weld metal with a coal-tar compound. If apolyurethane dielectric coating has been used, use a compatible polyurethanecoating.

(12) Backfilling.

(a) General. The Contractor will be required to backfill all trenches in accordancewith the requirements of Item 400, "Excavation and Backfill for Structures", exceptfor measurement and payment.

The backfill and clean-up of each section of main, i.e., from valve to valve, shallbegin immediately upon the completion of the hydrostatic test and shall continueuntil a final and complete clean-up of the section is obtained. Any portion of thetrench which is left open in excess of that required to facilitate hydrostatic testingmay be ordered closed by the Engineer.

Surplus excavated materials are to be used in the embankments or disposed of asdirected by the Engineer.

(b) Pipe Backfill for Water Mains.

(i) Open Cut. Following completion of the pipe joints being made up andinspected. All trenches shall be backfilled with excavated materials or anyother backfill material covered by this specification as approved by theEngineer. The portion from springline of the pipe (or from 150 millimeters ontop of the pipe if sand bedding is used) to the top of the trench shall bebackfilled in lifts not to exceed 225 millimeters loose measurement. (Providedthe trench is not located in sidewalks, roadways, roadway shoulders,driveways, etc. that are being used for automobile or pedestrian traffic). Thebackfill material shall be mechanically compacted by using vibratoryequipment or any other equipment acceptable to the Engineer so that nosettlement shall occur. In no case shall the density be less than 90 percent ofthe maximum dry density as determined in accordance with Test Method Tex-114-E. The Engineer reserves the right to perform compaction tests on an as-needed basis. Compaction by water tamping is prohibited.

Care shall be taken to see that no dirt, clods or trench sides are allowed to falland/or rest against the pipe prior to the completion of embedment or backfill.

58-75 50932-97

The allowable materials for backfill are listed in Subarticle 2.(16), "BackfillMaterial", of this specification. Backfilling and compaction shall continue inthis manner to the minimum elevation shown in the excavation and backfilldiagram.

(ii) Auger Pits. All auger pits shall be backfilled with bank run sand up to 300millimeters from the top of the natural ground. The final 300 millimeters ofthe backfill shall consist of 250 millimeters of native soil in the bottom and 50millimeters of bank run sand below the grass. The portion from the spring lineof the pipe to the top of the pit shall be backfilled in lifts not to exceed 225millimeters (loose measurement). The backfill shall be mechanicallycompacted by using vibratory equipment or any other equipment acceptable tothe Engineer, so that no settlement shall occur. The material should becompacted to a minimum of 90 percent of the maximum dry density atoptimum moisture content as determined in accordance with Test Method Tex-113-E or Tex-114-E. The Owner reserves the right to perform compactiontests on an as-needed basis. Compaction by water tamping is prohibited.

Care shall be taken to see that no dirt, clods or auger pit sides are allowed tofall and/or rest against the pipe prior to the completion of embedment orbackfill.

The allowable material for backfill, in auger pits shall only be bank run sand,described in Subarticle 2(16), "Backfill Material", of this specification.

(13) Valves and Fire Hydrants. Each valve and fire hydrant must be completely closedwhen placed in the pipe line.

Valves and hydrants shall be installed in accordance with AWWA C600, except wheremodified by this specification. Drainage shall be provided at the base of the hydrant inaccordance with AWWA C600.

Each hydrant shall be set at the location and grade indicated by the stakes and shall beplumbed and braced and shall be installed in accordance with AWWA's requirementsfor fire hydrant installation. If the barrel of a hydrant is to pass through a concrete slab,a piece of 25 millimeter thick preformed bituminous expansion joint material shall befitted closely around the section of the barrel passing through the concrete.

Locate nozzle centerline a minimum of 450 millimeters above the finished grade.

Place 300 millimeter x 300 millimeter yellow indicators (plastic, sheet metal, plywood,or other material approved by the Engineer) on pumper nozzles of new or relocated firehydrants installed on new mains not in service. Remove indicators after new main istested and approved by the Engineer.

(14) Tapping Sleeves and Valves.

(a) General.

(i) Install tapping sleeves and valves at the locations and using the sizes shown onthe plans.

59-75 50932-97

(ii) Thoroughly clean the tapping sleeve, tapping valve and pipe in accordancewith the manufacturer's instructions prior to installation.

(iii) Hydrostatically test the installed tapping sleeve to 1034 kilopascals (guage) fora minimum of 15 minutes. Inspect the sleeve for leaks, and remedy any leaksprior to the tapping operation.

(iv) When tapping concrete pressure pipe, size on size, use a shell cutter onestandard size smaller than that of the water line being tapped.

(v) Do not use Large End Bell (LEB) increases with a next size tap except forexisting asbestos-cement pipe.

(b) Installation.

(i) Tighten bolts in the proper sequence so that undue stress is not placed on thepipe.

(ii) Align the tapping valve properly and attach it to the tapping sleeve.

(iii) Make the tap with a sharp shell cutter using the following criteria:

1) For 300 millimeter and smaller taps, use a minimum cutter diameterapproximately 13 millimeters less than the nominal tap size.

2) For 400 millimeter and large taps, use the manufacturer's recommendedcutter diameter.

(iv) Withdraw the coupon and flush all cuttings from the newly-made tap.

(v) Wrap the completed tapping sleeve and valve in accordance with thisspecification.

(vi) Place the concrete thrust block behind the tapping sleeve (NOT over thetapping sleeve and valve).

(vii)Arrange for the mandatory inspection of the installation prior to backfilling.Completion of the inspection shall not be required before backfilling.

(viii)Backfill in accordance with this specification and as shown on the plans.

(15) Boxes for Valves.

(a) The cast-iron or ductile-iron pipe shall be cut to proper length and the box shall beassembled and braced as approved by the Engineer. Butterfly valves for sizes 750millimeters and larger will require manholes to be constructed over the operators.

(b) Concrete for valve box placement:

1. For locations in new concrete pavement, use strength and mix design of newpavement.

60-75 50932-97

2. For other locations, use class "A" concrete, conforming to the requirements ofItem 421, "Portland Cement Concrete."

(c) Install valve box and riser piping plumbed in a vertical position. Provide a 150millimeter telescoping freeboard space between riser pipe top butt end, and interiorcontact flange of valve box, for vertical movement damping. Riser may rest onvalve flange, or provide suitable footpiece to support riser pipe.

(d) After valve box has been set, aligned, and adjusted so that lid is level with finalgrade, pour a 600 millimeter by 600 millimeter by 200 millimeter thick concreteblock around the valve box. Center valve box horizontally within concrete block.

(e) Paint covers of new valve boxes in "Fluorescent Orange" when installed. Aftercompletion and acceptance by the City, repaint covers in "Black". This work isincidental and no separate payment will be made.

(16) Wet Connections. The Contractor shall make the wet connections, under the directionof the Engineer, in such a manner and at such hours as to minimize inconvenience to thepublic. When the existing mains have been cut or a plug removed for a connection, thework of making the connection shall progress without interruption until complete.

Whenever the Contractor desires to proceed with a wet connection without a completeshut-off, there will be no extra compensation for damages or extra work resulting fromthe incomplete shut- off.

The Utility owner shall operate all gate valves in the existing system and in sections ofcompleted mains which have been placed in service. The Contractor shall notify theUtility owner at least 48 hours in advance of making connections.

Wet connections which are 50 millimeters in diameter or smaller are sometimes referredto on the plans as 50 millimeter standard connections or gooseneck connections. Itemswhich may be necessary to complete these types of wet connections include corporationcock, saddle, copper tubing, brass fittings and 50 millimeter valves. These connectionsare not to be used or construed as any part of a 50 millimeter service line.

The Utility owner will handle at no cost to the Contractor, all operations involvingopening and closing valves for wet connections.

(17) Polyethylene Film Wrap. Except as noted on the plans, cast-iron and/or ductile-ironpipe (including fittings and other appurtenances) shall be wrapped with a polyethylenefilm. Fire hydrant barrels shall be wrapped.

Remove all lumps of clay, mud, cinders, etc., on pipe surface prior to installation ofpolyethylene encasement. Prevent soil or embedment material from becoming trappedbetween pipe and polyethylene. Fit polyethylene film to contour of pipe to effect asnug, but not tight; encase with minimum space between polyethylene and pipe.Provide sufficient slack in contouring to prevent stretching polyethylene where itbridges irregular surfaces, such as bell-spigot interfaces, bolted joints, or fittings, and toprevent damage to polyethylene due backfilling operations. Secure overlaps and endswith adhesive tape to hold polyethylene encasement in place until backfilling operationsare complete.

61-75 50932-97

For installations below water table and/or in areas subject to tidal actions, seal both endsof polyethylene tube with adhesive tape at joint overlap.

Repairs: Repair any cuts, tears, punctures, or damage to polyethylene with adhesivetape or with short length of polyethylene sheet or cut open tube, wrapped around pipe tocover damaged area, and secured in place.

Openings in Encasement: Provide openings for branches, service taps, blowoffs, airvalves, and similar appurtenances by making an X-shaped cut in polyethylene andtemporarily folding back film. After appurtenance is installed, tape slack securely toappurtenance and repair cut, as well as other damaged area in polyethylene, with tape.Service taps may also be made directly through polyethylene, with any resultingdamaged areas being repaired as described above.

Junctions between Wrapped and Unwrapped Pipe: Where polyethylene-wrapped pipejoins an adjacent pipe that is not wrapped, extend the polyethylene wrap to cover theadjacent pipe for a distance of at least one (1) meter. Secure the end withcircumferential turns of the tape. Wrap service lines of dissimilar metals withpolyethylene or suitable dielectric tape for a minimum clear distance of one (1) meteraway from cast-iron or ductile-iron pipe.

(a) Tubular Type Wrap. When the polyethylene film is supplied in tubular form, itshall be installed on the pipe prior to placing the pipe in the trench and in thefollowing manner:

Elevate the spigot end of the pipe; brush mud and debris from the pipe, and slip alength of film (approximately 600 millimeters longer than the joint of pipe) overthe joint of pipe. Wrap the film tightly around the spigot end, leaving about 300millimeters extending beyond the end of the pipe, and tape the edge down lightlywith polyethylene tape.

When the joint of pipe is picked up for placing in the trench, remove any remainingmud, clay or debris. Insert the spigot end into the bell end of the joint previouslyplaced, push home, and release the pipe into the trench. Pick up the pipe joint atthe bell, slide the film to a point back of the bell, and prepare a bell hole.

When the next joint is laid, pull the film beyond the bell so as to overlap the filmattached to the spigot of the new pipe joint. Wrap the film by folding itlongitudinally and tape securely in place to prevent damage during backfill. Do nottape the end that has just been slipped over the last bell but bind it with twine orother approved material.

At each corporation, draw the loose material up around the corporation base andseal it with tape to insulate the two (2) dissimilar metals.

Wrap all fittings and fire hydrant leads, and tape or bind the wrap with heavy twine.Fittings, such as bends and reducers, shall be wrapped similarly to the methodoutlined above. Specials, such as valves, tees, crosses, etc., shall be wrapped bysplitting, tucking and overlapping the polyethylene tube, then closing the fieldmade splices with the required tape. Material to cover the valves may be acquired

62-75 50932-97

from excess overlapping polyethylene tubing on adjacent pipe joints. Thepolyethylene tubing should be drawn over the bell of the pipe on either side andinsulated with field made seams as described above. All fittings and specials thatrequire concrete blocking shall be completely wrapped prior to placing concrete.

(b) Sheet Type Wrap. For sheet type wrap, the wrap may be applied around the pipeeither prior to or after pipe has been positioned in the trench. "Above ground"installation shall be similar to that described above for tubular installation. "Intrench" installation shall also be made in a manner similar to that described below.

(i) Cut the polyethylene sheet to a length approximately 600 millimeterslonger than pipe section. Center the length to provide a 300 millimeteroverlap on each adjacent pipe section, bunching it until it clears pipe ends.Wrap polyethylene around pipe so that it circumferentially overlaps topquadrant of pipe. Secure the cut edge of polyethylene sheet at intervals ofapproximately one (1) meter.

(ii) Lower wrapped pipe into trench and make up pipe joint with precedingsection of pipe. Make shallow bell hole at joints to facilitate installation ofpolyethylene. After completing joint, make overlap and secure ends.

(iii) Repair cuts, tears, punctures, or other damage to polyethylene. Proceedwith installation of next section of pipe in same manner.

(c) Auger Section Installation. Use cast-iron or ductile-iron pipe with a polyurethanecoating as specified in this item.

(d) A final seal against the intrusion of the backfill material shall be made bycompletely encasing the tapping sleeve with sheet vinyl of 200 micrometerthickness. Tape to secure this wrapping shall be that manufactured for this purposeof Polyken No. 900, Scotch Wrap No. 50 or approved equal.

(18) Sterilization of Mains and Testing for Leakage.

(a) Sterilization of Mains. The Utility owner will furnish water for chlorination andflushing without charge to the Contractor.

The Contractor shall furnish the necessary taps, risers and jumpers of such sizesand materials as are specified by the Engineer, and shall install the subject materialin the locations designated by the Engineer. Normally, each valved section of mainwill require two (2) 19 millimeter taps; however, on larger mains the Engineer mayorder that 38 millimeter or 50 millimeter taps and risers be used. The Contractorshall also furnish and install the necessary temporary blind flanges, sleeves, plugs,etc., as required to sterilize and pressure test the new mains.

Fire hydrants shall be used as blow-offs to flush newly constructed waterlines of200 millimeters diameter and greater.

After the pipe has been laid and backfilled, all newly laid pipe shall be sterilized.Unless otherwise specified on the plans the Utility owner, at his own expense, willfurnish the labor and materials necessary for the initial application of the sterilizing

63-75 50932-97

agent. Each valved section of pipe shall be slowly filled with water and all airexpelled from the pipe. Should taps at points of highest elevation be required toaccomplish this, they shall be furnished and installed by the Contractor. After themain is filled with water and all air expelled, the pipe shall be charged with thesterilizing agent and allowed to stand for 24 hours. Unless otherwise specified onthe plans the Utility owner will then flush the main with water. After flushing,samples will be drawn from the main and tested at a valid, testing facility approvedby the Engineer. After samples are drawn, the Contractor may then proceed withthe pressure test and any necessary repairs. If the samples do not pass, the pipeshall be re-sterilized until the samples taken are passed by the certified andapproved testing facility. Unless otherwise specified on the plans in the event thatmore than one sterilization of the main (or portion of the main) is required, alladditional sterilizations will be charged to the Contractor at rates established by theUtility owner.

(b) Testing for Leakage. Following the first sterilization test, all newly laid pipe shallbe subjected to a hydrostatic pressure of 862 kilopascals, unless otherwise shownon the plans. Where practicable, pipe lines shall be tested in length, between linevalves or plugs, not to exceed 457 meters unless otherwise approved by theEngineer. The pressure test shall be performed by means of a pump connected tothe pipe in a manner satisfactory to the Engineer. The Contractor shall furnish,install and operate the necessary connections, pump, meter and gauges. Prior torunning the pressure test, the meter shall be tested, sealed and approved (at theContractor's expense) by a certified testing facility approved by the Engineer. Theduration of the test shall not be less than eight (8) hours. If a large quantity ofwater is required to maintain pressure during the test, testing shall be discontinueduntil cause of water loss is identified and corrected.

The following general regulations shall be observed during each leakage test forcast-iron, ductile-iron prestressed concrete cylinder and PVC pipe.

Except for welded steel pipe in which no leakage is permitted, pipe lines, whensubjected to the specified pressure test, shall not show leakage in excess of 1.079liters/millimeter of diameter/kilometer/24 hours (or 27 liters/25 millimeters ofdiameter/kilometer/24 hours).

All portions of the pipe showing visible leaks shall be repaired regardless of thetotal leakage shown by the pressure test. Any cracked or defective pipes, fittings,valves or hydrants discovered by means of this pressure test shall be removed andreplaced with sound material by the Contractor. If the main is opened for anyreason, it shall then be re-sterilized until satisfactory samples are obtained. It shallalso be pressure tested until the requirements of this specification are met.

Immediately upon completion of sterilization and pressure testing, the Contractorshall remove all taps, risers, and blow-offs and shall backfill the remainder of thetrench in accordance with the requirements of this specification.

No payment shall be made to the Contractor for performing hydrostatic testing(Leakage Test).

64-75 50932-97

(19) Mains - Use of Completed Sections. The Utility owner shall be permitted to use andoperate any or all portions of the water mains which have passed the leakage test andhave been sterilized. Unless otherwise specified on the plans, the valves in suchcompleted sections shall be operated only with the express permission of the Utilityowner.

The use of the mains shall not be construed as acceptance of same and the Contractorwill not be relieved of any of his responsibilities for fulfilling the conditions of thecontract unless the mains are damaged due to negligence on the part of the Utilityowner.

(20) Mains - Lowering. When a main is to be lowered, the initial excavation shall be donein such a manner as to permit the mains to rest on a number of dirt benches. If soilconditions are unsatisfactory for dirt benches, wooden blocks shall be used to supportthe mains. The pipe shall then be attached by ropes, cable or chains to overheadsupports; the dirt benches or wooden blocks shall then be removed and the pipe slowlyand evenly lowered into position. After the mains have been lowered, each damagedjoint shall be repaired as directed by the Engineer.

(21) Copper Service Line Construction. The use of Hays-Seal and Mueller Companycatalog numbers to describe various fittings is not intended to be proprietary, but merelyto indicate clearly the respective types of fittings which are to be furnished.

(a) Installing Service Lines. Copper service lines in curb and gutter streets shall belaid with a minimum of 750 millimeters of cover from top of curb to the top of theservice line. Service lines laid in crowned streets with open ditches shall be laidwith a minimum of 750 millimeters of cover at the crown and with a minimum of450 millimeters of cover from the flow line of the ditch to the top of the serviceline. Service line locations shall be clear of all proposed paving and undergroundwork.

Care shall be exercised to keep the lines free of dirt and foreign matter at all times.Copper lines shall be put together in an entirely slack position and shall be free ofkinks. Service lines shall consist of one continuous run of copper tubing wherepossible. Bends shall be no greater than that originally found in the coil of tubingas packaged. For 38 millimeter and 50 millimeter copper tubing shipped in straightlengths, the following bend criteria shall be used: For 50 millimeter copper tubing,a maximum of one (1) 45 degree bend may be accomplished in a 1.22 metersection; for 38 millimeter copper tubing, a maximum of one (1) 45 degree bend in aone (1) meter section. No kinks, dents, flats or crimps will be permitted.

Meters should, in general, be located one (1) meter into the street right-of-way.Where this is not applicable, meters should be located approximately 300millimeters from the sidewalk on the curb side. If the present meter locationconflicts with proposed driveway turnouts or other proposed street improvements,the meter should be shifted to miss the obstruction and re-connected to thecustomer's service line. Meters shall be reset at positions such that the top of themeter will be 100 to 150 millimeters below the finished grade.

65-75 50932-97

Where plans call for salvaging and relocating meter, meter box and curb stop, thesematerials shall be removed with care, thoroughly cleaned, and inspected by theEngineer prior to installation in the new location. If the plans call for relocating themeter (other than at some point along the existing service line), a new service linewill be required.

Where it is necessary to cross a paved street, the service line shall be pushed underthe paving through a predrilled and prepared opening. Only full lengths of coppertubing shall be used and care shall be taken not to damage the tubing when pullingit through the prepared hole. A compression type union is only permitted if theContractor cannot span the required length with a full length of tubing.Compression type unions shall NOT be used under the paved street.

(b) Corporation Stop Installation. The main shall be tapped at a location such that astraight line passing through the meter and the corporation stop will be at 90degrees to the main. Taps shall be located in the upper portion of the main within45 degrees of the pipe springline. The cutting operation shall be performed with asharp shell cutter tool and shall be approved by the Engineer.

Taps for service lines shall conform to the requirements of the following tables.Taps shall be spaced a minimum of 600 millimeters apart.

PIPE TAPPING SCHEDULESERVICE SIZE, MILLIMETERSWATER MAIN

TYPE AND DIAMETER 19 25 38 50100mm Cast-Iron or Ductile-Iron

DSS,WBSS DSS,WBSS DSS,WBSS DSS,WBSS

100mm Asbestos-Cement WBSS WBSS DSS,WBSS DSS,WBSS100mm PVC(AWWA C900) DSS,WBSS DSS,WBSS DSS,WBSS DSS,WBSS150mm and 200mm Cast-Iron or Ductile-Iron

DSS,WBSS DSS,WBSS DSS,WBSS DSS,WBSS

150mm and 200mm Asbestos- Cement

DSS,WBSS DSS,WBSS DSS,WBSS DSS,WBSS

150mm and 200mm Cast-Iron or Ductile-Iron

DSS,WBSS DSS,WBSS DSS,WBSS DSS,WBSS

150mm and 200mm PVC (AWWA C900)

DSS,WBSS DSS,WBSS DSS,WBSS DSS,WBSS

300mm Cast-Iron or Ductile-Iron

DSS,WBSS DSS,WBSS DSS,WBSS DSS,WBSS

300mm Asbestos-Cement DSS,WBSS DSS,WBSS DSS,WBSS DSS,WBSS300mm PVC (AWWA C900)

DSS,WBSS DSS,WBSS DSS,WBSS DSS,WBSS

400mm and Up Cast-Iron or Ductile-Iron

DWBSS DWBSS DWBSS DWBSS

400mm and Up Asbestos- Cement

DWBSS DWBSS DWBSS DWBSS

400mm and Up PVC (AWWA C900)

DWBSS DWBSS DWBSS DWBSS

DSS - DUAL STRAP SADDLESWBSS - WIDE BAND STRAP SADDLESDWBSS - DUAL WIDE BAND STRAP SADDLES* Mueller H-15092, or equal

66-75 50932-97

(c) Curb Stop Installation. Curb stops or angle stops shall, in all cases, be set at theouter end of the service line just ahead of the meter. Secure opening in the curbstop to prevent unwanted material from entering. Eighth bend or quarter bendcouplings may be used to accomplish close quarter turns in the service line. In all19 millimeter and 25 millimeter services, a meter coupling or swivel nut meterspud curb stop shall be installed ahead of the meter. A straight meter couplingshall also be installed on the outlet end of the meter. A new curb stop shall beinstalled when the service line is extended.

(d) Sequence of Work. Open trench for proposed service line or prepare jacking andreceiving pits.

Install corporation stop in a workmanlike manner using proper equipment.

Install copper service line and connect to corporation stop.

Install curb stop on the meter end of the service line.

With curb stop open, and prior to connecting service line to meter, opencorporation stop and flush service line adequately. Close curb stop, leavingcorporation stop in full open position.

Check service line for apparent leaks. Repair leaks before proceeding.

Connect service line to meter and if necessary adjust meter location. Care shall betaken to make sure that the inlet side of meter is connected to water service line.Momentarily open curb stop to verify proper registration of meter.

Backfill all excavations; tamp the backfill material in place to the density of the soilin the adjacent trench walls.

If the meter is to be relocated, the meter box shall be replaced so that it is centeredover the meter with top of lid flush with finished grade. When the meter must belocated in driveways or sidewalks, the Contractor will be required to furnish andinstall an approved traffic type meter box with cast-iron lid.

(22) Cutting and Plugging of Water Mains. Where plans call for the abandonment ofwater mains, the following general procedure shall be followed:

After the replacement main has been constructed, sterilized, tested and placed inservice, and all services transferred to the replacement main, the main to be abandonedshall be located and traced back to the feeder main and at this point cut and plugged atthe tee. Normally, this is done by installing a plug, clamp and a concrete thrust block.In cases of 38 millimeter or 50 millimeter Corporation Cock or TS & V connections, thevalve shall be removed and a cap or plug installed at the Tee. In no instances shall theline to be abandoned be valved off at the nearest valve or cut and plugged other than atthe supply main.

All ends or openings in abandoned mains shall be adequately plugged or capped in anapproved manner and all excavation backfill and any street surfaces replaced, to the

67-75 50932-97

Engineer's satisfaction. This shall be done in accordance with Subarticles 3.(1),"Excavation" and 3.(9), "Backfilling", of this specification.

All surface identification shall be removed, i.e., valve boxes and fire hydrants. Valveboxes, when in improved streets other than shell, may be poured full of concrete withthe cap permanently removed.

(23) Service Lines of Public Utilities. Where any pipe or conduit of a public utilitycorporation crosses the water main trench, such pipe or conduit shall be supported in amanner satisfactory to the Engineer.

Should the Contractor consider it necessary for a utility corporation to relocate utilitylines or other improvements, the Contractor must notify the Engineer in advance. TheEngineer will make the necessary arrangements with the utility corporation if heconsiders it imperative that the change be made.

(24) Relocation of Meter Vaults. Existing valves, meters and strainers inside a vault shallbe salvaged and returned to the utility owner or as designated on the plans.

Pipe, valves, service lines and other appurtenances shall be installed in accordance withthe pertinent Articles of this specification or as directed by the Engineer.

In general the type of meter vault shall be installed as shown on the plans or asapproved by the Engineer.

(a) Precast Concrete Vault. The precast concrete vault shall be constructed andfurnished as shown on the plans.

The precast concrete vault shall be set level on a minimum 75 millimeter bed ofsand in an excavation and brought to grade. Piping shall then be installed and sandshall be backfilled around vault.

(b) Cast-in-Place Concrete Vault. The cast-in-place concrete vault shall beconstructed as shown on the plans. Key the walls to the floor slab and form to thedimensions as shown on the plans. Minimum wall thickness shall be 100millimeters. Cast walls monolithically. One (1) cold joint will be allowed whenvault depth exceeds 3.6 meters. Set the frame for the cover while the concrete isstill green.

(c) Frame and Cover. Frame and cover shall be constructed as shown on the plans.

In grass areas, the frame and cover shall be set 50 to 75 millimeters above naturalground or finished grade and parallel to it (maximum angle from horizontal shall be20 degrees). Backfill shall be sloped away from meter.

In sidewalk areas, the frame and cover shall be set 13 to 25 millimeters aboveadjacent concrete and parallel to it. Replacement concrete shall be sloped awayfrom meter to meet adjacent concrete.

(d) Inspections. The following inspections shall be made jointly by the Engineer andrepresentatives of the Utility owner:

68-75 50932-97

(1) Site Location Inspection - proposed meter location must be approved prior tocommencing work.

(2) Final Inspection - to be conducted after all backfill s in place, cover installed,cleanup completed, and surface is restored.

(25) Adjustment of Existing Surface Structures.

(a) Valve Boxes. Salvage and reuse valve box. Remove and replace 150 millimeterductile-iron riser pipe with suitable length for depth of cover required to establishthe adjusted elevation to accommodate actual finished grade.

Reinstall valve box and riser piping plumbed in a vertical position. Provide aminimum 150 millimeter telescoping freeboard space between the riser pipe topbutt end and interior contact flange of valve box for vertical movement damping.

After valve box has been set, aligned, and adjusted so that top lid is level with finalgrade, place a 600 millimeter by 600 millimeter by 200 millimeter thick concreteblock around the valve box. Center the valve box horizontally within the concretebox.

(b) Meter Boxes. Salvage and reuse meter boxes when possible. Reinstall inaccordance with manufacturer's recommendations. Any damage to the meter boxduring relocation or service transfer shall be at the expense of the Contractor.

If the existing meter box requires replacement, the Contractor may obtain a newbox from the Utility owner by providing adequate documentation of the existingand proposed locations.

(c) Meter Vaults. Adjustment of all meter vaults will be in accordance with thedetails as shown on the plans. The Contractor shall salvage and reuse accesscovers.

(26) Relocation of Water Meters and Boxes. Existing curb stops, meters, unions, andmeter boxes shall be salvaged, cleaned, inspected, and installed at the new location inaccordance with specifications in this section. When the meter and box is relocated, itwill be moved the minimum distance to enable access for new connections. Anydamage to the meter box during relocation or service transfer shall be at the expense ofthe Contractor.

If the Contractor is unable to salvage the existing boxes, new boxes can be obtainedfrom the Utility owner with proper documentation of the existing and proposed locationof the meter.

With the approval of the Engineer, meter boxes, when located adjacent to existingpavement, may be relocated when this operation will facilitate construction or decreasethe costs. Approval of the Engineer must be obtained in writing in all cases and allrelated costs such as excavation, piping, meter box relocation, removal and replacementof paving, etc. will be incidental to the project and born by the Contractor.

69-75 50932-97

(27) Installation of Split Casing. The Contractor shall notify the Utility owner, not lessthan 48 hours in advance, of any work planned involving existing water lines. Waterlines to be encased shall not have more than 6 meters exposed at any time.

150 millimeter x 150 millimeter x 31.5 millimeter neoprene pads shall be placedbetween the split casing sections and the top and bottom of the water lines atapproximately 1.8 meter spacings or as directed by the Engineer.

The trench when completed and shaped to receive the casing shall be of sufficient widthto provide free working space for satisfactorily installing the casing and backfillingunder and around the casing.

The split casing shall be held in place for welding by hinges, coupling bands or anyother method acceptable to the Engineer.

All welded joints shall conform to the requirements of AWWA Standard C 206. Weldsshall be such as to develop the full strength of the pipe throughout the joint.

The ends of the encasement pipe shall be sealed with casing and seals in accordancewith Section 2.(2)(a), "Steel Carrier Pipe", to prevent entrance of excessive groundwater.

(28) Modifications for Cathodic Protection.

(a) General. Cathodic protection systems shall be in accordance with SpecialSpecification Item, "Cathodic Protection Systems for Large Diameter Water Main",as specified herein and as shown on the plans.

References to steel pipe shall be interpreted to apply to tape coated welded steelpipe. Where damage occurs to pipe coatings during welding process. Affectedarea is to be refurbished to original condition.

Prestressed concrete cylinder pipe shall be modified for cathodic protection asrequired to ensure that all metallic components, including the wire wrap are tiedtogether. The wire shall be attached to the cylinder at each end of the joint bywelding in accordance with paragraph 5.5.2 of AWWA C205.

(b) Bonded Joints.

(i) Where rubber gasket bell and spigots are provided, the Contractor shallprovide for bonded joints by either welding a strap or clip between the bell andthe spigot of each joint or by providing a thermite welded cable between thebell and the spigot of each joint. All pipe, whether installed in a tunnel or opencut, shall have bonded joints, except where insulating flanges are to beprovided. Where joints are welded for thrust restraint, no additional bondingwill be required.

(ii) Bonding Strap or Clip. The strap or clip for bonding the bell to the spigotshall be free of all foreign material that may increase the contact resistancebetween wire and strap or clip.

70-75 50932-97

Unless otherwise noted, insulation kits shall be provided at connections to theexisting water system or at locations to isolate one (1) type of cathodic systemfrom another type, between the water main, and extra piping or as shown onthe plans.

(29) Removing and Salvaging Fire Hydrants and Water Meters. Fire hydrants and watermeters to be removed and salvaged shall be delivered to their owner at the location setforth on the plans or as directed by the Engineer.

(30) Installation of the Nonmetallic Pipe Detection System. The nonmetallic pipedetection system shall be installed concurrently with the proposed pipe placement. Thisinstallation shall be as specified by the manufacturer and/or as approved by theEngineer.

(31) Removing Water Main and/or Removing Water Main with Casing. Removingwater mains and/or water mains with casing shall be in accordance with Item 100,"Preparing Right of Way" or as shown on the plans. This shall include the removal anddisposal of all pipe and appurtenances as shown on the plans or as directed by theEngineer. Excavation and backfill, required, will not be measured or paid for directlybut will be considered subsidiary to this Item.

4. Measurement. This Item will be measured as follows:

(1) Water Main Pipe and Steel Casing will be measured by the linear meter, of thevarious sizes and types specified. The water mains and/or casing will be measuredalong the axis of the pipe and no deductions will be made for valves or fittings.Reducers shall be classed as pipe of the size of the larger end.

(2) Split Steel Casing will be measured by the linear meter, of the various sizes shown onthe plans, complete in place.

(3) Jacking, Tunneling, Boring or Augering, for water main and steel casing, will bemeasured by the linear meter, of the sizes, types and wall thicknesses (applicable onlyfor casing) specified.

(4) New Copper Service Lines will be measured by each service line, installed.

Short Side service line shall refer to service connections to be made to meters on thesame side of the street on which the supply main is located. Long side service line shallrefer to service connections to be made to meters on the opposite side of the street onwhich the supply main is located, or from the center of the street where the supply mainis located in the center of the street.

(5) Tapping Sleeves and Valves and Butterfly Valves will be measured by eachassembly, of the various sizes, with the valve box installed.

(6) Fire Hydrants will be measured by each assembly installed, for all depths. It shall bethe Contractor's responsibility to install the fire hydrant such that it meets the standardinstallation requirement of this specification and/or the manufacturer's specifications.

(7) Meters and Vaults will be measured by each assembly constructed, complete in place.

71-75 50932-97

(8) Air Release and Vacuum Relief Valves will be measured by each assembly, of thevarious sizes, with the valve box installed.

(9) Pressure Reducing Stations will be measured by the lump sum unit constructed,complete in place.

(10) Blow Off Valves will be measured by each assembly, of the various sizes and types,with the valve box installed.

(11) Removing Fire Hydrants will be measured by each removed and disposed of properly.

(12) Removing Water Valves and Boxes will be measured by each removed and disposedof properly.

(13) Removing and Relocating Meters and Boxes will be measured by each assemblyremoved, cleaned and installed at the new location.

(14) Removing Meters and Vaults will be measured by each assembly removed.

(15) Removing and Salvaging Water Meters will be measured by each assembly removedand salvaged.

(16) Removing and Salvaging Fire Hydrants will be measured by the each.

(17) Removing and Relocating Water Meters and Meter Vaults will be measured by eachassembly removed and relocated.

(18) Adjusting Meter Vaults will be measured by each assembly adjusted.

(19) Adjusting Meter Boxes will be measured by each assembly adjusted.

(20) Lowering Water Mains will be measured by the linear meter, of the sizes and types ofpipe lowered.

(21) Cutting and Plugging Water Mains will be measured by the each, of the sizesindicated.

(22) Removing Pressure Reducing Stations will be measured by each complete pressurestation removed.

(23) Wet Connections will be measured by each connection, of the sizes specified.

(24) Extra Hand Excavation or Extra Machine Excavation will be measured by the cubicmeter in its original position. Excavation performed by manual labor at the locationsspecifically designated by the Engineer, and which is not included under or subsidiaryto other bid items contained in this specification, shall be considered Extra HandExcavation or Extra Machine Excavation.

5. Payment. The work performed and materials furnished in accordance with this Item andmeasured as provided under "Measurement" will be paid for at the unit prices bid for theitems of work hereinafter described. These prices shall be full compensation for furnishingand hauling all materials; for placing or installing the materials; for inspection and testing;

72-75 50932-97

and for all other items of material, labor, equipment, tools and incidentals necessary tocomplete the work in accordance with the plans and specifications.

(1) Payment for water main pipe and steel casing will be made at the unit prices bid for"Water Main Pipe (Cast-Iron)", "Water Main Pipe (Steel)", "Water Main Pipe (Ductile-Iron)", "Water Main Pipe (Copper)", "Water Main Pipe (Polyvinyl Chloride)(PVC)","Water Main Pipe (Prestressed Concrete Cylinder Pipe)(PCCP)" and "Casing (Steel)",of the various sizes and types specified, installed by the open cut method.

Unless otherwise shown on the plans or specifications, excavation, unsuitable excavatedmaterial disposal backfill and the material for backfill for the complete installation ofthe water main system will not be paid for directly but will be considered subsidiary tothis bid item.

(2) Payment for split steel casing will be made at the unit price bid for "Split Steel Casing",of the various sizes, installed by the open cut method.

(3) Payment for jacking, tunneling, boring or augering water main will be made at the unitprice bid for "Jacking, Tunneling, Boring or Augering (Water Main)" of the sizes andtypes specified. This price shall include furnishing the pipe.

Payment for jacking, tunneling, boring or augering steel casing will be made at the unitprice bid for "Jacking, Tunneling, Boring or Augering Casing (Steel)" of the sizes, typesand wall thicknesses (applicable only if exceeding minimum thickness, shown inSection 2.(2)(6), "Steel Casing Pipe", of this specification) specified. This price shallinclude the casing. Water mains placed in the casing will be paid for by the appropriatebid item.

Excavation, backfill, backfill material and disposal of the unsuitable excavated materialfor jacking, tunneling, boring or augering pits will not be paid for directly but will beconsidered subsidiary to these bid items.

(4) Payment for copper service lines will be made at the unit price bid for "Service Line(Short Side 16mm to 25mm)", "Service Line (Long Side 16mm to 25mm)", "ServiceLine (Short Side 38mm to 50mm)" and "Service Line (Long Side 38mm to 50mm)",installed. This price shall be full compensation for all labor, materials, excavation andbackfill required to install the facility complete in place, including connection to thecustomer's service line.

(5) Payment for tapping sleeves and valves and butterfly valves will be made at the unitprice bid for "Gate Valve", "Tapping Sleeve and Valve", and "Butterfly Valve", of thevarious sizes, with the valve box installed.

(6) Payment for fire hydrants will be made at the unit price bid for "Fire Hydrant" installed,for all depths.

Any adjustment required either in the flow line of the water main or to the barrel lengthof the fire hydrant will not be paid for directly but will be considered subsidiary to thisbid item.

73-75 50932-97

(7) Payment for meters and vaults will be made at the unit price bid for "Meter and Vault"constructed, complete in place.

(8) Payment for air release and vacuum relief valves will be made at the unit price bid for"Air Release and Vacuum Relief Valves", of the various sizes, with the valve boxinstalled.

(9) Payment for pressure reducing stations will be made at the unit price bid for "PressureReducing Stations". This price shall be full compensation for performing the necessaryexcavation, backfill and finish grading constructing the concrete structure, andfurnishing and installing all station appurtenances addressed under Article 2.,"Materials" of this specification.

(10) Payment for blow off valves will be made at the unit price bid for "Blow Off Valve" ofthe various sizes and types, with the valve box installed.

(11) Payment for removing fire hydrants will be made at the unit price bid for "RemovingFire Hydrant". This price shall include removing valves from the existing location,disposal of valves and plugging at the tee. Excavation and backfill required forremoving fire hydrants will not be paid for directly but will be considered subsidiary tothis bid item.

(12) Payment for removing water valves and boxes will be made at the unit price bid for"Removing Water Valves and Boxes". Excavation and backfill required for removingwater valves and boxes will not be paid for directly but will be subsidiary to this biditem.

(13) Payment for removing and relocating meters and boxes will be made at the unit pricebid for "Removing and Relocating Meter and Box".

(14) Payment for removing meters and vaults will be made at the unit price bid for"Removing Meter and Vault". This includes salvaging of the meter strainers and valvesand delivering them to their owner at the location shown on the plans or as directed bythe Engineer.

(15) Payment for removing and salvaging water meters will be made at the unit price bid for"Removing and Salvaging Water Meters". This price shall include removal from theexisting location and delivery to the owner. Excavation and backfill and finish gradingrequired for removing the water meters will not be paid for directly but will beconsidered subsidiary to this bid item.

(16) Payment for removing and salvaging fire hydrants will be made at the unit price bid for"Removing and Salvaging Fire Hydrant". The salvaging of fire hydrants will be a cashreimbursement to the owner by the Contractor where the fire hydrants will become theproperty of the Contractor or the Contractor will deliver the fire hydrants to the ownerat the location shown on the plans. Excavation, backfill and finish grading required forremoving fire hydrants will not be paid for directly but will be considered subsidiary tothis bid item.

(17) Payment for removing and relocating water meters and meter vaults will be made at theunit price for "Removing and Relocating Water Meter and Meter Vault".

74-75 50932-97

(18) Payment for adjusting meter vaults will be made at the unit price bid for "AdjustingMeter Vault". This price shall be full compensation for furnishing all requiredmaterials, including backfill as required, excavation, tools, labor, equipment andincidentals required to complete the work.

(19) Payment for adjusting meter boxes will be made at the unit price for "Adjusting MeterBox".

(20) Payment for lowering water mains will be made at the unit price bid for "LoweringWater Mains", of the sizes and types of pipe lowered. This price shall be fullcompensation for lowering and adjusting pipes, valves, boxes and service lines whichare connected thereto. Excavation and backfill required for lowering water mains willnot be paid for directly but will be considered subsidiary to this bid item.

(21) Payment for cutting and plugging water mains will be made at the unit price bid for"Cut and Plug Water Main" of the sizes indicated. This price shall be full compensationfor performing all excavation, backfill, finish grading and other incidental itemsrequired to abandon or cut and plug the water main as set forth herein. Where grout isrequired, as shown on the plans, it will not be paid for directly but will be consideredsubsidiary to this bid item.

(22) Payment for removing pressure reducing stations will be made at the unit price bid for"Removing Pressure Reducing Station". This price shall be full compensation forperforming the necessary excavation, backfill, finish grading pipe removal, structureremoval, and all tools, equipment and incidentals necessary to perform this work.

(23) Payment for wet connections will be made at the unit price bid for "Wet Connections",of the sizes specified.

(24) Payment for extra hand excavation or extra machine excavation will be made at the unitprice bid for "Extra Hand Excavation" or "Extra Machine Excavation". This price shallbe full compensation for all labor, hand tools, machines, dewatering and handling anddisposal of any excess excavated material not suitable for bedding and backfill for thisproject.

Trench excavation protection or temporary special shoring for trenches which weregreater than 1.5 meters in depth, and/or sloping the sides of these trenches to precludecollapse, will be measured and paid for as required by Item 402, "Trench ExcavationProtection" or Item 403, "Temporary Special Shoring".

No direct payment will be made for furnishing and placing bedding material, this workwill be considered subsidiary to the various bid items.

No direct payment will be made for fittings, including necessary concrete thrustblocking, pipe clamps, nipples, pipe coatings, lubricants, etc. These items will beconsidered subsidiary to the water mains in which they are installed. In addition,fittings required due to plan changes or alterations in line and grade will not bemeasured and paid for directly but will be considered subsidiary to the water mains inwhich they are installed.

75-75 50932-97

No direct payment will be made for furnishing and installing taps, risers, jumpers, blindflanges, cast-iron sleeves, plugs, reducers etc., as required to sterilize and pressure testthe new mains. This work will be considered subsidiary to the various bid items. Inaddition, the Contractor shall perform, without extra compensation, all necessaryexcavation and backfill, site graphing, and maintenance until completion of pressuretesting.

Unless otherwise specified on the plans, the work performed and materials furnished tosupport the pipes or conduits of public utilities will not be paid for directly but will beconsidered subsidiary to the various bid items.

No direct payment will be made for furnishing and/or installing the nonmetallic pipedetection system. The work and materials necessary for the system will be consideredsubsidiary to the various bid items. In addition, the Contractor shall ensure that thedetection system is complete and operational and satisfactory to the owner of the utility.

No direct Payment will be made for adjusting valve boxes, this work shall beconsidered subsidiary to the various bid items.