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1993 Specifications CSJ 0151-09-029

SPECIAL SPECIFICATION5915

Water Mains and Sanitary Sewers

1. Description. This Item shall govern for all materials, equipment, and labor necessary forthe installation of all water and wastewater lines, drain lines, and any and all distributionlines connected to the various structures as shown on the plans. Material, equipment andlabor listed herein and not indicated on the City of Austin plans or estimate shall not be apaid item.

2. Contractor Experience. For this project, for microtunnel construction, the Contractor mustsubmit the “Statement of Contractor’s Experience” form signed and notarized for ownerevaluation and approval.

3. Materials. Each piping system shall be installed using the materials designated on the plansand in details for each particular system. The materials so designated shall be furnished inaccordance with all material requirements of the attached City of Austin specialspecifications, except for measurement and payment. When required on a project,reinforcing steel, structural steel, flexible base, preparation of right of way, furnishing andplacing topsoil, seeding for erosion control, concrete structures, concrete for structures, andsoil retention blankets shall conform to Department Standard Specifications Item 440,"Reinforcing Steel", Item 442, "Metal for Structures", Item 247, "Flexible Base", Item 100,"Preparing Right of Way, Item 160, "Furnishing and Placing Topsoil", Item 164, "Seedingfor Erosion Control", Item 420, "Concrete Structures", Item 421, "Portland CementConcrete", and Item 169, "Soil Retention Blanket" respectively, except for measurement andpayment.

4. Geotechnical Baseline Conditions for Water and Wastewater Utilities. The UtilityContractor shall submit a letter stating that he/she has read and understands the City ofAustin Special Specifications Item entitled “Geotechnical Baseline Conditions for Waterand Wastewater Utilities” prepared specific for this project. The Special Specifications Itementitled “Geotechnical Baseline Conditions for Water and Wastewater Utilities” andsubsidiary specifications to it are part of the utility work contract.

5. Construction Methods. Each system shall be installed in accordance with the constructionmethods detailed on the plans and as described in the attached City of Austin specialspecifications, except that all environmental protection measures shall be in accordance withthe standard Department methods and as detailed on the City of Austin plans. No street cutpermits will be required for this contract within State right of way. However, cuts madewithin the City of Austin right of way will require a street cut permit. Contact the C.O.A.Public Works Department, Construction Inspection Division at (512) 974-7128 for furtherdetails.

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When blasting is specified within the City of Austin plans, any blasting required will beperformed in strict compliance with standard TxDOT procedures.

The utility facility, when located within state right of way, shall be placed in accordancewith the TxDOT Utility Accommodation Policy (Title 43 T.A.C., Sections 21.31-21.55).

Where nonmetallic pipe is installed longitudinally a durable metal wire shall be concurrentlyinstalled or other means shall be provided for detection purposes.

Trench excavation protection shall be accomplished as required by the provisions of, Part1926, Subpart P-Excavations, and applicable appendices of the Occupational Safety andHealth Administration's Standards and Interpretations and City of Austin SpecialSpecifications Item entitled “ Trench Safety Systems”.

All pipelines crossing under roadways shall be encased in the type and size of encasementpipe indicated on the plans. Casings shall extend a minimum five (5) feet beyond each curbor edge of shoulder.

The Contractor shall provide surveying services for construction of the project and shallprovide “cut sheets” to the City of Austin and TxDOT ( a requirement of City of AustinSpecial Specification Item “Pipe”).

The Contractor shall provide monthly “as-built” information on the drawings to ensure allitems are installed and all changes are documented.

6. Testing. Testing of each system shall be performed as outlined in the attached City ofAustin special specifications except for reinforcing steel, structural steel, flexible base andconcrete for structures, which, when required on a project, shall be done in accordance withDepartment Standard Specifications Items 440, 442, 247 and 421 respectively.

Retesting charges will be deducted from payments to the Contractor for any test which failsto meet the required standards described in the attached City of Austin SpecialSpecifications.

7. Disinfection of Potable Water Lines. Sterilization of all potable water lines shall beperformed as described in the attached City of Austin Special Specifications Item entitled“Pipe”.

8. Safety. The Contractor shall at all times exercise reasonable precautions for the safety ofworkers and the public, and shall comply with applicable provisions of all Federal and Statesafety laws and regulations. The safety precautions taken and their adequacy shall be thesole responsibility of the Contractor.

9. Warranty Agreement. A warranty agreement between the City of Austin and Contractormust be executed to cover this item of work. The cost of the warranty agreement issubsidiary to this item of work. The warranty agreement includes the requirement of amaintenance bond for not less than 10% of this item's cost for a one-year warranty periodbeginning after final completion.

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10. Measurement. When required on a project, work and acceptable materials as prescribed bythis Item will be measured for payment in accordance with the methods indicated on theplans and as follows:

(1) "Jacking or Boring Pipe" will be measured by the lineal foot of pipe complete in place.Such measurement will be made between the ends of the pipe along the flowline asinstalled. (City of Austin Special Specifications entitled “Jacking or Boring Pipe”).

(2) Frames, grates, rings and covers ( City of Austin Special Specifications entitled“Frames, Grates, Rings and Covers”), safety end treatment and any restoration will notbe measured.

(3) “Adjusting Structures” of the type specified and “Relocating Structures” of the typespecified will be measured as each adjustment, complete in place. When a pay item isincluded in the contract for service pipe to the structure to be adjusted, the service pipewill be measured as "Pipe" below. When a pay item is not included in the contract forservice pipe, this pipe will be considered subsidiary to these bid items.

(4) “Concrete Encasement” of the size specified and “Encasement Pipe” of all types, sizes,placement method (if applicable) and classes (if applicable), will be measured per linealfoot of pipe, complete in place. Such measurement will be made between the ends ofthe encasement pipe along the centerline as installed. (City of Austin SpecialSpecifications Item entitled “Concrete Encasement and Encasement Pipe”).

(5) "Manholes" will be measured as follows:

(a) Manholes of the diameter and type specified on the Drawings will be measured aseach manhole, complete in place, all depths including shop drawings for 5’ Dia.precast wastewater manholes. (City of Austin Special Specifications Item entitled“Manholes”).

(b) Abandonment of manholes, will not be measured, but will be considered subsidiaryto "Manholes".

(6) "Manhole Rehabilitation", will be measured as each manhole of all sizes, complete inplace. (City of Austin Special Specifications Item entitled “Manhole Rehabilitation”).

(7) Trench Safety Systems shall be measured by lineal foot along the centerline of pipetrench only, conforming to the specifications.

(8) "Pipe" of the diameter and type specified will be measured as follows:

(a) When a pay item for "Fittings" is included in the contract, "Pipe" will be measuredby the linear foot along the centerline, complete in place. This measurement for"Pipe" will not include the length of fittings, valves or other items included in thecontract for separate pay.

(b) When a pay item for "Fittings" is not included in the contract, "Pipe" will bemeasured by the lineal foot horizontally along the centerline of the pipe, completein place. This measurement for "Pipe" will include the length of fittings, valves,vertical stacks for wastewater services or other items included in the contract. Other

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items will not include manholes or junction boxes. Where manholes or junctionboxes are included in lines of pipe, that length of pipe tying into the structure wallwill be included for measurement, but no other portion of the structure length orwidth will be so included.

(c) The Contractor shall provide for the flow of water and wastewater around thesection or sections of pipe designated for rehabilitation, including active services inthe rehabilitation section. The bypass shall be made as required by City of AustinSpecial Specification entitled “Pipe”. This work will not be measured and will beconsidered subsidiary to Item “Pipe”.

(d) Where the pipe is to connect to an existing pipe, measurement of "Pipe" will bemade to the visible end of the existing pipe or the outside surface of the fittingflange to which the "Pipe" connects.

(9) “Controlled Low Strength Material” will not be measured nor paid for directly but shallbe considered subsidiary to the various bid items in the contract. (City of Austin SpecialSpecification entitled “Controlled Low Strength Material”).

(10) "Concrete Trench Cap" will be measured by the linear foot, complete in place. (City ofAustin Standard Detail number 510S-1 entitled “Concrete Trench Cap”).

(11) "Wet Connections" of the diameter of the pipes specified will be measured as eachconnection, complete in place.

(12) "Pressure Taps" of the diameter of the pipes specified will be measured as each tap,complete in place, including valves.

(13) "Cast Iron or Ductile Iron Fittings" will be measured by the ton, complete in place,when included in the contract as a pay item. Fittings for pipe sizes larger than 24 inchesare subsidiary to the pipe and no measurement or payment will be made.

(14) "Valves" of the type and size, as specified on the Drawings and in City of AustinSpecial Specifications Item “Water Valves” will be measured by each unit, complete inplace, all depths.

(15) "Fire Hydrants/Drain Valve Assemblies" as specified on the Drawings and in City ofAustin Special Specifications Item “Water Valves” will be measured per each, completein place, all depths. Blue reflective delineator for identifying location of the newlyinstalled fire hydrants shall be considered subsidiary to fire hydrants.

(16) "Automatic Air Release Assemblies" will be measured per each, complete in place.

(17) "Concrete Retards" will be measured by the cubic yard or by each, complete in place.(City of Austin Special Specifications Item entitled “Concrete Retards” and City ofAustin Detail number 593S-1 entitled “Concrete Retard”).

(18) "Adjusting Water Meters” and “Relocating Water Meters" of the sizes specified will bemeasured per each, complete in place, including new meter boxes and concrete vaults,traffic bearing boxes and lids, where called for on the plans. When a pay item is notincluded in the contract for service pipe, this pipe will be considered to these bid items.

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(19) "Lateral Services (Installation or Reconnection)(Min one and a half inches (1 and 1/2”)Dia. copper) will be measured per each, complete in place, of the existing service linepipe size or minimum of one and a half inches diameter copper. New pipe will beinstalled between the meter and the new or existing water main.

(20) Measurement for the microtunnel of the type of pipe and size specified will be made byactual linear foot of pipe installed, complete in place, within specified line-and-grade.This price shall be full compensation for spoil and slurry handling, stockpiling, loading,transporting and disposal of the excavated materials, for furnishing all materials,handling, placing, labor, tools, equipment and incidentals necessary to complete thework. Subsidiary to this bid item are the requirements included in the City of Austinfollowing Special Specifications: “Tunnel Excavation by Microtunnel BoringMachine”, “Installation of Carrier Pipe”, “ Microtunnel Access Shaft and RetentionSystems”, “Low Density Cellular Concrete for Backfill”, “Centrifugally cast fiberglassReinforced Polymer Mortar Pipe and Fittings for 24” Wastewater MicrotunnelConstruction”, “Geotechnical Baseline Conditions for Water and Wastewater Utilities”,“Concrete Encasement and Encasement Pipe”, “Trench Safety Systems”, “Pipe” andmandatory submital of “Statement of Microtunnel Contractor Experience”.

(21) Measurement for microtunnel access shafts and retention systems, complete in place,regardless of the horizontal dimensions, will be made by actual vertical foot fromfinished lid elevation to the shaft bottom. This price shall be full compensation for spoiland slurry handling, stockpiling, loading, transporting and disposal of the excavatedmaterials, for furnishing all materials, handling, placing, labor, tools, equipment andincidentals necessary to complete the work. Subsidiary to this bid item are therequirements included in the City of Austin following Special Specifications: “TunnelExcavation by Microtunnel Boring Machine”, “Installation of Carrier Pipe”, “Microtunnel Access Shaft and Retention Systems”, “Low Density Cellular Concrete forBackfill”, “Geotechnical Baseline Conditions for Water and Wastewater Utilities”,“Concrete Encasement and Encasement Pipe”, “Trench Safety Systems”, “Pipe” andmandatory submital of “Statement of Microtunnel Contractor Experience”.

11. Payment. When the following is required on a project, the work performed, materialsfurnished in the plans in accordance with this Item and measured as provided under"Measurement" will be paid for at the unit prices bid for the items hereinafter described.

Payment shall be full compensation for all staking and engineering work, testing,disinfecting, furnishing and installing all materials, accessories and incidentals necessary tocomplete the work prescribed in this specification and as detailed on the plans. Saidpayment shall also be full compensation for all excavation and backfilling, all freight,loading, unloading, handling of materials, labor, tools and equipment and incidentalsnecessary to complete the work.

(1) Payment for jacking or boring pipe will be made at the unit price bid for "Jacking orBoring Pipe", of the type, size and class specified. The bid price shall be fullcompensation for furnishing all materials, pipe and liner materials required, for allpreparation, hauling and installing of same, and for all labor, tools, equipment andincidentals necessary to complete the work, including excavation, backfilling and

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disposal for surplus materials. (City of Austin Special Specifications entitled “Jackingor Boring Pipe”).

(2) Frames, grates rings and covers (City of Austin Special Specifications entitled “Frames,Grates, Rings and Covers”), safety end treatment and any restoration will not be paidfor directly, but shall be considered subsidiary to one of the pay items identified in thebid.

(3) Payment for adjusting structures and relocating structures will be made at the unit pricebid for "Adjusting Structures", and “Relocating Structures”of the type specified. Thebid price shall be full compensation for furnishing all materials including meter boxesand concrete vaults, handling, placing, repositioning & adjustment requirements, labor,tools, taps, equipment and incidentals necessary to complete the work.(City of AustinSpecial Specification Item entitled “Adjusting and Relocating Structures/WaterMeters”).

(4) Payment for Concrete Encasement and Encasement Pipe will be made at the unit bidprice per lineal foot for “Concrete Encasement” of the size specified and “EncasementPipe” of the size, type, classes (if applicable) and placement method (if applicable)specified. The bid price shall include full compensation for furnishing all materials,handling, placing, labor, tools, equipment and incidentals necessary to complete thework. (City of Austin Special Specification Item “Concrete Encasement andEncasement Pipe”).

(5) Payment for manholes will be made at the unit price bid for "Manholes", of thediameter and type specified. The bid price shall be full compensation for furnishing allconcrete, reinforcing steel, brick, mortar, aluminum and castings, frames, grates, ringsand covers and for all other materials, labor, tools, equipment and incidentals requiredto complete the work. (City of Austin Special Specification Item entitled “Manholes”).Payment will include compensation for the Contractor’s responsibility to submitengineered “Shop Drawings” for 5’ Dia. precast wastewater manholes detailing steelrequirements for applicable earth and hydrostatic loads for approval by City of Austinbefore wastewater line construction begins. Abandonment/removal of all manholes thatwill be retired as a result of this project will not be paid for directly but shall beconsidered subsidiary to related bid items.

(6) Payment for manhole rehabilitation will be made at the unit price bid for "ManholeRehabilitation". This price shall be full compensation for furnishing all concrete,reinforcing steel, brick, mortar, aluminum and castings, frames, grates, rings and coversand for all other materials, labor, tools, equipment and incidentals required to completethe work for all types and sizes required. (City of Austin Special Specification Itementitled “Manhole Rehabilitation”).

(7) Payment for Trench Safety Systems will be made at the unit bid price for “TrenchSafety Systems” per centerline lineal foot of trench per City of Austin SpecialSpecification Item entitled “Trench Safety Systems”. The unit bid price shall includefull compensation for designing, furnishing, installing the system; for dewatering,maintenance, replacement and removal of the Trench Safety Systems and for sloping,

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special clearing, and excavation necessary to safely implement the Trench SafetySystem Plan.

(8) Payment for pipe will be made at the unit price bid for "Pipe", of the diameter and typespecified. This price shall be full compensation for project traffic control, surveying forconstruction and providing cut sheets, clearing, all bedding materials, fittings, (exceptfor cast iron or ductile iron fittings 24 inches and smaller in size), caps, bulkheads,joints, wyes, vertical stacks, two way clean-outs, connections, plugs, lugs, pipecoatings, connection to the existing system, repair of existing pipe, laying of pipe, cutand plug existing pipe that is to remain in place, removal/disposal of existing pipescheduled for abandoment, with the exception of the AC pipe, disposal of surplusmaterials, laying of pipe, excavation, backfilling, salvaging existing valves and firehydrants, installation of tree protection fence and soil retention blankets and all labor,tools and incidentals necessary to complete the work. Payment shall also represent fullcompensation for removal and replacement of existing and proposed pavement,placement of permanent pavement, curb, drainage structures, driveways, and any otherimprovements damaged during construction. Permanent restoration to the existing orbetter conditions for easements. No separate payment will be made for concreteblocking, thrust blocks, welded joints and harnessed joints required for thrust restraint.The bid item price shall also include any and all steel plates required, pot-holing forexisting utility elevations, and plugging and abandoning utilities that will be retired as aresult of this project. ( City of Austin Special Specification Item entitled “Pipe”).

(9) “Controlled Low Strength Material” backfill will not be paid for directly but shall beconsidered subsidiary to other bid items. (City of Austin Special Specification Itementitled “Controlled Low Strength Material”).

(10) Payment for concrete trench cap will be made at the unit price bid for "Concrete TrenchCap", of the type specified. This price shall be full compensation for furnishing allmaterials, handling, placing, labor, tools, equipment and incidentals necessary tocomplete the work.

(11) Payment for wet connections will be made at the unit price bid for "Wet Connections",of the type and size specified. This price shall be full compensation for furnishing allmaterials, handling, placing, labor, tools, equipment, and for all work required to makethe connection and place the pipe in service, except that cast iron or ductile iron fittingsshall be paid for as a separate item.

(12) Payment for pressure taps will be made at the unit price bid for "Pressure Taps", for thetype and size specified, complete in place. This price shall be full compensation forfurnishing all materials, including valves, handling, placing, labor, tools, equipment andfor all necessary excavation, backfill, blocking, anchoring and for all work required tomake the tap and keep the pipe in service.

(13) Payment for cast iron or ductile iron fittings will be made at the unit price bid for "CastIron or Ductile Iron Fittings", of the type specified for fitting sizes 24 inches andsmaller. Fitting sizes larger than 24 inches will not be paid for directly but shall beconsidered subsidiary to the pipe. This price shall be full compensation for furnishingall materials, handling, placing, labor, tools, equipment and incidentals necessary to

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complete the work according to ANSI A 21.10 (AWWA C/110) and ANSI A 2153-88(AWWA C153) scheduled weights for mechanical joint fittings furnished. Thesescheduled weights will be considered as final and no compensation will be made foramounts over these. Steel cylinder pipe fittings and welded steel pipe fittings will not bepaid for separately but shall be considered subsidiary to the item "Pipe". Glands, boltsand gaskets shall be subsidiary to the fittings and will not be paid for directly.

(14) Payment for valves will be made at the unit price bid for "Valves", for the type and sizespecified, complete in place, all depths. This price shall be full compensation forfurnishing all materials, handling, placing, concrete bearing pads, labor, tools,equipment and incidentals including, valve stem casing and cover, excavation, settingand adjusting to proper grade and anchoring in place. (City of Austin SpecialSpecification Item entitled “Water Valves”).

(15) Payment for fire hydrant/drain valve assemblies will be made at the unit price bid for"Fire Hydrant/Drain Valve Assemblies". This price shall be full compensation forfittings between the main line and the fire hydrant, setting, adjusting to grade, anchoringin place, and other appurtenances necessary for proper operation; but shall not includepipe and valve between the main line and fire hydrant/drain valve. The unit price bidshall be full compensation for furnishing and installing all materials, labor, tools,equipment, and incidentals necessary to complete the work. Payment shall also includeall labor and other incidentals for salvaging of newly abandoned fire hydrants withinlimits of construction for this project and delivery to a storage site directed by the ownerrepresentative. (City of Austin Special Specification Item entitled “Water Valves”).

(16) Payment for automatic air release assemblies will be made at the unit price bid for"Automatic Air Release Assemblies". This price shall include the main line tap oroutlet, all pipe, valves, fittings, box or vault and cover, and other appurtenancesnecessary for proper operation. The unit price bid shall be full compensation forfurnishing and installing all materials, labor, tools, equipment, and incidentals necessaryto complete the work.

(17) Payment for concrete retards will be made at the unit price bid for "Concrete Retards",for the type specified. This price shall be full compensation for all excavation,reinforcing, furnishing, hauling and placing all materials required in the construction,disposal of excavated material and for all manipulation, labor tools, equipment andincidentals necessary to complete the work.

(18) Payment for adjusting or relocation of water meters will be made at the unit price bidper each for "Adjusting Water Meters", of the sizes specified, complete in placeincluding meter box and concrete vaults. This price shall be full compensation forfurnishing all materials, handling, placing, labor, tools, equipment and incidentalsnecessary to complete the work.

(19) Payment for lateral services will be made at the unit price bid for "Lateral Services”(Installation or Reconnection)(Min. one inch and a half copper (1 and ½ inches) Dia.)".This price shall be full compensation for furnishing all materials, handling, placing,labor, tools and incidentals necessary for the installation of a new service line between

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the meter and the new or existing water main, existing size or a minimum 1 and ½inches copper .

(20) Payment for the Microtunnel of the type of pipe and size specified will be made byactual linear foot of pipe installed, complete in place, within specified line-and-grade.This price shall be full compensation for spoil and slurry handling, stockpiling, loading,transporting and disposal of the excavated materials, for furnishing all materials,handling, placing, labor, tools, equipment and incidentals necessary to complete thework. Subsidiary to this bid item are the requirements included in the City of Austinfollowing Special Specifications: “Tunnel Excavation by Microtunnel BoringMachine”, “Installation of Carrier Pipe”, “ Microtunnel Access Shaft and RetentionSystems”, “Low Density Cellular Concrete for Backfill”, “Centrifugally cast fiberglassReinforced Polymer Mortar Pipe and Fittings for 24” Wastewater MicrotunnelConstruction”, “Geotechnical Baseline Conditions for Water and Wastewater Utilities”,“Concrete Encasement and Encasement Pipe”, “Trench Safety Systems”, “Pipe” andmandatory submital of “Statement of Microtunnel Contractor Experience”.

(21) Payment for microtunnel access shafts and retention systems, complete in place,regardless of the horizontal dimensions, will be paid for vertical foot from finished lidelevation to the shaft bottom. This price shall be full compensation for spoil and slurryhandling, stockpiling, loading, transporting and disposal of the excavated materials, forfurnishing all materials, handling, placing, labor, tools, equipment and incidentalsnecessary to complete the work. Subsidiary to this bid item are the requirementsincluded in the City of Austin following Special Specifications: “Tunnel Excavation byMicrotunnel Boring Machine”, “Installation of Carrier Pipe”, “ Microtunnel AccessShaft and Retention Systems”, “Low Density Cellular Concrete for Backfill”,“Geotechnical Baseline Conditions for Water and Wastewater Utilities”, “TrenchSafety Systems”, “Pipe” and mandatory submital of “Statement of MicrotunnelContractor Experience”.

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Item No. 402SControlled Low Strength Material

402S.1 Description

This item governs Controlled Low Strength Material (CLSM) used for trenchbackfill and for filling abandoned culverts, pipes, other enclosures, and for otheruses as indicated on the drawings, Standard Details or as approved by theEngineer or designated representative. CLSM is a low strength, self-compacting, flowable, cementitious material used in lieu of soil backfill. It isintentionally prepared at low strength to allow for future removal usingconventional excavation equipment.

The CLSM shall be composed of Portland cement or fly ash, or both, filleraggregate and water. The CLSM, specified for use in filling abandonedculverts, pipes, or other enclosures, shall contain a settlement compensator, inaddition to the other ingredients, to minimize settlement of the CLSM within theenclosure.

Normal Set CLSM shall be specified whenever the material will remainuncovered or will not be subjected to traffic or other loads within 24 hours afterplacement. Fast Set CLSM shall be specified whenever the material will becovered, subjected to traffic or other loads within 24 hours, or needed toexpedite construction.

CLSM can be used for permanent subgrade repairs below the base layer, butshall not be used for permanent pavement repairs. For temporary trafficapplications, a minimum 2 inch (50 mm) cap composed of Hot Mix-Cold LaidAsphaltic Concrete (TxDoT Standard Specification Item 334) shall be placed onthe CLSM.

This specification is applicable for projects or work involving either inch-poundor SI units. Within the text and accompanying tables, the inch-pound units aregiven preference followed by SI units shown within parentheses.

402S.2 Submittals

The submittal requirements of this specification item include:

A. Certification by the Portland Cement supplier that no hazardous waste isused in the fuel mix or raw materials.

B. A mix design submittal including the results of unconfined compressivestrength tests, air entrainment (if applicable), flow consistency, hardenedunit weight, and timed Ball Drop and corresponding Penetrometer tests.

C. Certifications and test results for the cement fly ash, and admixtures.D. Particle-size gradation and specific gravity tests on the filler aggregate.

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402S.3 Materials

A. Cement

Portland cement shall conform to ASTM C 150, Type I (General Purpose).

Portland cement, that is manufactured in a cement kiln fueled by hazardouswaste (30 Texas Administrative Code, Section 335.1), shall be prohibited.This restriction shall apply to any other specification, Special SpecificationItem, Special Provision, Standard Detail or instructions concerning the useof Portland cement materials. The Contractor shall maintain a record ofsource for each batch. The Supplier of the Portland Cement shall certifythat no hazardous waste is used in the fuel mix or raw materials.

B. Fly Ash

Fly ash shall conform to the requirements of Standard Specification ItemNo. 405, "Concrete Admixtures" and TxDOT Specification Item 437.

C. Filler Aggregate

Filler aggregate shall consist of sand, stone screenings, pavement millingcuttings or other granular material that is compatible with the other mixturecomponents. The filler aggregate shall be fine enough to stay in suspensionto the extent required for proper flow without segregation, and, in the caseof filling of enclosures, for minimal settlement. Filler aggregate shall havea Plasticity Index (TxDOT Test Method Tex-106-E) less than 15 and shallconform to the following gradation:

Sieve Designation US (SI) Percent Passing No. 200 (75µm) 0 - 10

D. Mixing Water

Mixing water shall conform to the requirements of Standard SpecificationItem No. 403, "Concrete for Structures".

E. Settlement Compensator

An air entraining admixture with a higher than usual dosage, which meetsthe requirements of Standard Specification Item No. 405, "ConcreteAdmixtures", shall be used as a settlement compensator. The settlementcompensator may be introduced to the CLSM at the job site by placementof prepackaged admixture in capsules or bags in the mixing drum inaccordance with the admixture manufacturer's recommendations.

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402S.4 Mix Design

The proportioning of CLSM shall be the responsibility of the Contractor. The Contractorshall furnish a mix design conforming to the requirements herein, for review andapproval by the Engineer or designated representative. The mix design shall be preparedby a qualified commercial laboratory and then reviewed and signed by a registeredProfessional Engineer licensed in the State of Texas.

The Mix Design submittal must include:

A. Test results for unconfined compressive strength, air entrainment (ifapplicable), flow consistency, hardened unit weight, and timed Ball Drop(ASTM C-360) and corresponding Penetrometer tests (with a concretepocket penetrometer),

B. Certifications and test results for the cement, fly ash, and admixtures, and

C. Results of particle-size gradation and specific gravity tests on the filleraggregate. The submittal shall include Penetrometer tests performedevery thirty minutes until the Ball Drop test shows a 2-inch (50 mm)indentation, as well as the predicted Penetrometer reading thatcorresponds to a 3-inch (75 mm) Ball Drop indentation. Particle-sizegradation shall be determined using a series of sieves that gives no fewerthan five uniformly spaced points for graphing the entire range of particlesizes larger than a No. 200 sieve (75-µm).

The Contractor shall perform the work required to substantiate the design at nocost to the City, including all testing. Approved mix designs shall be valid forone year, provided there are no changes in the type, source, or characteristics ofthe materials during that year.

At the end of one year, the mix design may be submitted for renewal, providedthat:

A. field tests of the CLSM during the year have been satisfactory,B. there have been no changes in type or source of the materials of the mix,

andC. the characteristics of the materials have not changed significantly since

the original submittal.

The Contractor shall also submit certifications and test results for the cement, flyash and admixtures, and particle-size gradation and specific gravity test resultsfor the filler aggregate. The Contractor shall compare results of tests made onthe filler aggregate at the end of the year to the results of tests reported in theoriginal submittal. Gradation changes less than ten percent in percent passingany sieve and specific gravity changes less than five percent shall not beconsidered significant.

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402S.5 Strength

The CLSM mix designs shall meet the unconfined compressive strengthrequirements outlined in the table below. The compression tests shall beconducted in accordance with TxDOT Method Tex-418-A, using approvedunbonded caps on specimens with four-inch (100 mm) diameter and eight-inch(200 mm) height [or three-inch (75 mm) diameter by six-inch (150 mm) highspecimens if a smaller capacity loading device gives more accurate results].

Unconfined Compressive Strength, psi (mPa)Age Normal Set CLSM Fast Set CLSM3 hours — 35 (240) minimum24 hours 35 (240) minimum —28 days 300 (2.0) maximum 300 (2.0) maximum

402S.6 Flow Consistency

Flow consistency shall be established in tests involving the use of a six-inch(150 mm) length by three-inch (75 mm) diameter open-ended straight tubingmade of steel, plastic or other non-absorbent material that is non-reactive withcement or fly ash. The tube shall be placed with one end on a horizontal flatsurface and held in a vertical position. The tube shall then be filled to the topwith CLSM. The top surface shall be struck off with a suitable straight edge andany spillage shall be removed from the base of the tube. Within five secondsthereafter the tube shall be raised carefully, using a steady upward lift with nolateral or torsional motion. The entire test, from the start of filling until removalof the tube, shall be completed within 1½ minutes without interruption.

After removal of the tube, the spread of the CLSM shall be measuredimmediately along two diameters that are perpendicular to one another. Theaverage of those two measurements is defined as the flow consistency of themix. The flow consistency of the CLSM shall be considered satisfactory if acircular-type spread of the mix occurs without segregation and a flowconsistency (average diameter of spread) of 8 inches (200 mm) or more isachieved.

402S.7 Air Entrainment

Air entraining admixture shall be added as a settlement compensator, wheneverthe CLSM will be used to fill an enclosure (Section 402S-1). The dosage shallbe sufficient to result in an air content of 15 to 25 percent (as determined byTxDOT Method Tex-416-A) at the time of placement of the CLSM.

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402S.8 Field Strength Tests

Ball Drop or Penetrometer tests shall be used to determine, when the CLSM hasdeveloped sufficient strength to be covered or subjected to traffic or other loadsas approved by the Engineer or designated representative.

The Ball Drop test shall be performed according to the latest version of ASTMC-360. An indentation diameter of three inches (75 mm) or less, and theabsence of a sheen or any visible surface water in the indentation area shallindicate that the CLSM has achieved the desired strength. Because trench widthand depth may affect the test results, the Contractor may perform this test on acontrol sample of CLSM in a two-foot (600 mm) square by six-inch (150 mm)deep container.

Penetrometer tests using a hand-held, spring reaction-type device commonlycalled a concrete pocket penetrometer, shall be performed on the surface of theCLAMS. A Penetrometer reading, equal to or greater than the value establishedin the mix design (Section 402S.4) for a Ball Drop test indentation of 3-inches(75 mm), shall indicate that the CLSM has achieved the desired strength.

402S.9 Construction Methods

A. GeneralThe height of free fall placement of the CLSM shall not exceed four feet(1.2 meters). Since CLSM is considered to be self-compacting, a vibratorshall not be allowed. The CLSM shall not be covered with any overlyingmaterials or subjected to traffic or other loads until the Ball Drop test orthe Penetrometer test shows acceptable results (Section 402S.8) or untilthe CLSM has been in place a minimum of 24 hours for Normal SetCLSM and a minimum of 3 hours for Fast Set CLSM. Curing of theCLSM will not be required.

B. Utility Line BackfillAfter the utility pipe has been placed and the proper bedding materialplaced in accordance with the details on the drawings, the trench may beimmediately backfilled with the CLSM to the subgrade level shown on thedrawings, Standard Details 1100S-6A, B, C & D, 430S-4 and 511S-13 oras directed by the Engineer or designated representative.

C. Culvert Backfill

Care shall be taken to prevent movement of the structure. If the pipe orstructure moves either horizontally or vertically, the CLSM and thestructure shall be immediately removed and the pipe or structure re-laid toproper line and grade.

D. Other Backfill

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CLSM may be used for backfill material in lieu of soil as shown on thedrawings, Standard Details or as approved by the Engineer or designatedrepresentative.

E. Filling Abandoned Culverts, Pipe, or other Enclosures

The CLSM shall be placed in a manner that allows all air or water, or both,to be displaced readily as the CLSM fills the enclosure.

402S.10 Acceptance Testing During Construction

The Engineer or designated representative may perform flow consistency, airentrainment, and unconfined compressive strength tests to determine if theCLSM meets the specification requirements. The number and frequency ofacceptance tests will be determined by the Engineer or designated representative.

402S.11 Measurement and Payment

Work performed and materials furnished as prescribed by this item will not bemeasured nor paid for directly but shall be considered subsidiary to the variousbid items in the contract.

End

SPECIFIC CROSS REFERENCE MATERIALSStandard Specification Item 402S, “Controlled Low Strength Material”

City of Austin Standard DetailsDesignation Description430S-4 Concrete Backfill Under Curb & Gutter

506S-14 Control or Mini Manhole

511S-13A Water Valve Box Adjustment to Grade W/ Full DepthConcrete

511S-13B Water Valve Box Adjustment to Grade W/ Concrete andH.M.A.C.

1100S-6A Narrow Excavation Next to C&G - Trench Width 0.3 M (12")& Less

1100S-6B Narrow Excavations - Trench Width 0.3 M (12") & Less1100S-6C Excavation Next to C&G - Trench Width Greater than 0.3 M

(12")1100S-6D Excavations - Trench Width Greater than 0.3 M (12")

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City of Austin Standard Specification Items

Designation DescriptionItem No 403 Concrete for StructuresItem No 405 Concrete Admixtures

Texas Department of Transportation: Standard Specifications for Constructionand Maintenance of Highways, Streets, and BridgesDesignation DescriptionItem No. 334 Hot Mix-Cold Laid Asphaltic Concrete PavementItem No. 420 Concrete StructuresItem No. 421 Portland Cement ConcreteItem No. 437 Concrete Admixtures

RELATED CROSS REFERENCE MATERIALS

Texas Department of Transportation: Manual of Testing ProceduresDesignation DescriptionTex-106-E Method Of Calculating the Plasticity Index of SoilsTex-416-A Air Content of Freshly Mixed Concrete By The Pressure

MethodTex-418-A Compressive Strength of Cylindrical Concrete

American Society for Testing and Materials (ASTM)Designation DescriptionASTM C 150 Portland CementASTM C 360 Ball Penetration in Fresh Portland Cement ConcreteASTM C 403 Time of Setting of Concrete Mixtures by Penetration

Resistance

City of Austin Standard Specification ItemsDesignation DescriptionItem No. 504S Adjusting StructuresItem No. 506S ManholesItem No. 508S Miscellaneous Structures and AppurtenancesItem No. 510 Pipe

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Item No. SS501Jacking or Boring Pipe

SS501.1 Description

This item shall govern furnishing and installing of encasement pipe by methods ofjacking or boring as indicated on the Drawings and in conformity with this specification.This item shall also include, but not be limited to other constructions activities such astraffic control measures, excavation, removal of all materials encountered in jacking orboring pipe operations, disposal of all material not required in the work, grouting voidsbetween the encasement pipe and surrounding excavated material, seal wrap installation,backfilling and re-vegetation.

This specification is applicable for projects or work involving either inch-pound or SI units. Within the text and accompanying tables, the inch-poundunits are given preference followed by SI units shown within parentheses.

SS501.2 Submittals

The submittal requirements for this specification item shall include:

A. Shop drawings identifying proposed jacking or boring methodcomplete in assembled position

B. Trench Safety Plan including pits, trenches and sheeting or bracingif necessary,

C. Design for jacking or boring head,

D. Installation of jacking or boring supports or back stop,

E. Arrangement and position of jacks and pipe guides,

F. Grouting plan,

G. Encasement pipe,

H. Casing Spacers, and

I. Boot or seal wrap.

SS501.3 Materials

A. Pipe

Carrier pipe and encasement pipe shall conform to City of Austin SpecialSpecification Item Nos. SS505, "Concrete Encasement and EncasementPipe" and SS510, "Pipe" and shall be size, type materials, thickness andclass indicated on the Drawings, unless otherwise specified.

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B. Grout

Grout used to fill voids between the encasement pipe and surroundingexcavated material shall consist of 1 part Portland cement and 4 partsfine, clean sand mixed with water. The grout shall have a consistencysuch that it will flow into and completely fill voids.

C. Casing Spacers

Casing spacers shall conform to SPL WW-575.

D. Boots or Seal WrapBoots and seal wrap for sealing the ends of the encasement pipe shall be of a typeand material approved by the Engineer.

SS501.4 Construction Methods

A. General.The Contractor is responsible for:

1. Adequacy of jacking and boring operations,2. Installation of support systems as indicated on the Drawings,3. Provision of encasement and carrier pipe, and4. Execution of work involving the jacking operation, the wet or dry

method of boring and the installation of encasement pipesimultaneously.

The Contractor shall have sole responsibility for the safety of the jacking andboring operations and for persons engaged in the work. The Contractor'sattention is directed to the Construction Industry Occupational Safety andHealth Administration (OSHA) Standards (29 FR 1926/1920) as published inU.S. Department of Labor publication OSHA 2207, latest revision, withparticular attention to Subpart S. The Contractor shall conform to therequirements in accordance with TxDOT Standard Specification Item 402,"Trench Excavation Protection" and shall provide an appropriate TrenchSafety Plan.

When the grade of the pipe at the jacking or boring end is below the groundsurface, suitable pits or trenches shall be excavated to provide sufficient roomto conduct the jacking or boring operations and for placement of end joints ofthe pipe. In order to provide a safe and stable work area, the excavated areashall be securely sheeted and braced to prevent earth caving in accordancewith the Trench Safety Plan.

The location of the work pit and associated traffic control measures requiredfor the jacking or boring operations shall conform to the requirements of the

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City of Austin Transportation Criteria Manual and TxDoT Manual onUniform Traffic Control Devices.

Where installation of pipe is required under railroad embankments, highways,streets, or other facilities by jacking or boring methods, construction shall beundertaken in such a manner that it will not interfere with operation of anyrailroad, street, highway, utility or other facility and shall not weaken ordamage any embankment or structure. All appropriate permits shall beacquired prior to the initiation of the work.

During construction operations, and until the work pits are backfilled and fillmaterial compacted, traffic barricades and warning lights to safeguard trafficand pedestrians shall be furnished and maintained by the Contractor. TheContractor shall submit the proposed pit location and traffic control plan forreview by the Engineer or designated representative. The Review by theEngineer or designated representative, however, will not relieve theContractor from his responsibility to obtain specified results in a safe,workmanlike manner.

When grade of pipe at jacking or boring end is below ground surface,suitable pits or trenches shall be excavated for the purpose of conductingthe jacking or boring operations and for joining pipe. Work shall besecurely sheeted and braced as indicated on the Trench Safety Plan toprevent earth caving and to provide a safe and stable work area.

The pipe shall be jacked or bored from the low or downstream end, ifpossible. Minor lateral or vertical variation in the final position of pipefrom line and grade established by Engineer or designated representativewill be permitted at the discretion of Engineer or designatedrepresentative provided that such variation is regular and occurs only inone direction and that the final grade of the flow line conforms to thespecified direction.

When conforming to details indicated on the drawings, but the bottom of thework pit is unstable or excessively wet or the installation of water andwastewater pipe will result in less than 30 inches (750 mm) of cover, theContractor shall notify the Engineer or designated representative. TheEngineer or designated representative may require the Contractor to install aconcrete seal, cradle, cap or encasement or other appropriate action.

Immediately after jacking or boring is complete and the encasement pipe isaccurately positioned and approved for line and grade, the clear spacebetween the pipe and the surrounding excavated material shall be completelyfilled by pressure grouting for entire length of installation.

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After placement of the carrier pipe is complete, the ends of the encasementpipe shall be sealed using a boot or seal wrap, designed specifically for thatpurpose and approved by the Engineer.

As soon as possible after the carrier pipe(s) and end seals are completed, thework pits or trenches, which are excavated to facilitate these operations, shallbe backfilled. The backfill in the street ROW shall be compacted to not lessthan 95 percent of the maximum density conforming to TxDOT Test MethodTex-114-E, “Laboratory Compaction Characteristics & Moisture-DensityRelationship of Subgrade & Embankment Soil”. Field density measurementswill be made in accordance with TxDOT Test Method Tex-115-E, “FieldMethod for Determination of In-Place Density of Soils and Base Materials”.

Where the characteristics of soil, size or size of proposed pipe dictate thattunneling is more satisfactory than jacking or boring, a tunneling method maybe submitted for acceptance by Engineer or designated representative.

B. Jacking

Heavy duty jacks suitable for forcing the pipe through the embankment shallbe provided. In operating the jacks, an even pressure shall be applied to alljacks used so that the pressure will be applied to the pipe uniformly aroundthe ring of the pipe. A suitable jacking frame or back stop shall be provided.The pipe to be jacked shall be set on guides properly braced together, tosupport the section of the pipe and to direct it in the proper line and grade.The complete jacking assembly shall be placed in order to line up with thedirection and grade of the pipe. In general, the embankment material shall beexcavated just ahead of the pipe, the material removed through the pipe andthe pipe forced through embankment by jacking, into the space thus provided.

The excavation for the underside of the pipe, for at least 1/3 of thecircumference of the pipe, shall conform to the contour and grade of the pipe.A clearance of no more than 2 inches (50 mm) may be provided for the upperhalf of the pipe. This clearance shall be tapered to zero at the point whereexcavation conforms to contour of pipe.

The distance that excavation shall extend beyond the end of the pipe dependson the character of material encountered, but it shall not exceed 2 feet (0.6meter) in any case. This distance shall be decreased, when directed by theEngineer or designated representative, if the character of the material beingexcavated makes it desirable to keep the advance closer to the end of thepipe.

The Contractor may use a cutting edge of steel plate around head end of thepipe extending a short distance beyond the end of pipe with inside angles orlugs to keep cutting edge from slipping back onto the pipe.

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When jacking of the pipe is begun, all operations shall be carried on withoutinterruption, insofar as practical, to prevent the pipe from becoming firmlyset in the embankment.

Any pipe damaged in jacking operations shall be removed and replaced bythe Contractor at its entire expense.

C. Boring

The boring shall proceed from a work pit provided for the boring equipmentand workmen. Excavation for the work pits and the installation of shoringshall be as outlined in the Trench Safety Plan. The location of the pit shall beapproved by the Engineer or designated representative. The boring shall bedone mechanically using either a pilot hole or the augur method.

In the pilot hole method an approximate 2 inch (50 mm) pilot hole shall bebored the entire length of the crossing and shall be checked for line and gradeon the opposite end of the bore from the work pit. This pilot hole shall serveas the centerline of the larger diameter hole to be bored.

When the augur method is used, a steel encasement pipe of the appropriatediameter equipped with a cutter head to mechanically perform the excavationshall be used. Augurs shall be of sufficient diameter to convey the excavatedmaterial to the work pit.

Excavated material will be removed from the working pit and disposed ofproperly. The use of water or other fluids in connection with the boringoperation will be permitted only to the extent to lubricate cuttings. Waterjetting will not be permitted.

In unstable soil formations, a gel-forming colloidal drilling fluid, that consistsof at least 10 percent of high grade carefully processed bentonite, may beused to consolidate the drill cuttings, seal the walls of the hole and furnishlubrication to facilitate removal of the cuttings from the bore.

D. Joints

If reinforced concrete pipe is used, the joints shall be in accordance withTxDOT Specification Item 464, “Reinforced Concrete Pipe”.

SS501.5 Measurement and Payment

Work performed and materials furnished as prescribed by this item will bemeasured and paid by the appropriate unit bid price identified in TxDOTSpecial Specification “Water and Wastewater Utilities”.

End

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SPECIFIC Cross Reference MaterialsSpecification Item 501S, "Jacking or Boring Pipe"

City of Austin Water and Wastewater Standard Products List (SPL)Designation DescriptionWW-575 Casing Spacers

City of Austin Special Specification ItemsDesignation DescriptionItem No. SS505 Concrete Encasement and Encasement PipeItem No. SS510 Pipe

TxDOT Standard Specifications For Construction AndMaintenance Of Highways, Streets, And BridgesDesignation DescriptionItem 464 Reinforced Concrete PipeItem 402 Trench Excavation Protection

TxDOT Testing ProceduresDesignation DescriptionTex-114-E Laboratory Compaction Characteristics & Moisture

Density Relationship of Subgrade & Embankment SoilTex-115-E Field Method for Determination of In-Place Density of

Soils and Base Materials

TxDOT Manual on Uniform Traffic Control Devices (MUTCD)Designation DescriptionMUTCD Part VI Traffic Controls for Street and Highway Construction,

Maintenance, Utility and Incident Management OperationsMUTCD Section 6C Channelizing DevicesMUTCD Section 6C-8 Barricade DesignMUTCD Section 6C-9 Barricade ApplicationMUTCD Section 6E Lighting DevicesMUTCD Section 6F Control of Traffic Through Work Areas

City of Austin Transportation Criteria ManualDesignation Description

Section 8 Traffic ControlSection 8.5.5.E Typical Applications/Bore Pits

RELATED Cross Reference MaterialsSpecification Item 501S, "Jacking or Boring Pipe"

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City of Austin Standard DetailsDesignation DescriptionDetail 501S-1 Encasement Detail w/ Casing Spacers

TxDOT Standard SpecificationsDesignation DescriptionItem 476 Jacking, Boring or Tunneling PipeItem 502 Barricades, Signs and Traffic Handling

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Item No. S503Frames, Grates, Rings and Covers

SS503.1 Description

This item shall govern furnishing and installation of frames, grates, rings and covers forinlets, manholes and other structures indicated on the Drawings.

This specification is applicable for projects or work involving either inch-poundor SI units. Within the text, the inch-pound units are given preference followedby SI units shown within parentheses.

SS503.2 Submittals

The submittal requirements of this specification item include manufacturer,model number, description, painting requirements and characteristics of frames,grates, rings, covers, height adjustment insert and nuts and bolts required forcompletion of the work.

SS503.3 Materials

The Contractor shall submit descriptive information and evidence that the materials andequipment the Contractor proposes for incorporation in the Work is the kind and qualitythat satisfies the specified functions and quality. The City of Austin Water andWastewater Utility Standard Products Lists (SPLs) form a part of these Specifications.Contractors may, when appropriate, elect to use products from the SPLs; however,submittal to the Engineer or designated representative is still required. If the Contractorelects to use any materials from these lists, each product shall be completely and clearlyidentified by its corresponding SPL number when making the product submittal.

The purpose of the SPLs is to expedite the review by the Engineer or designatedrepresentative and, if necessary, the City of Austin Water and Wastewater UtilityStandard Products Committee of Contractor product submittals. The SPL’sshould not be interpreted as being a pre-approved list of products necessarilymeeting the requirements for a given construction Project. Items contained in theSPL cannot be substituted for items that are shown on the Drawings, called for inthe specifications, or specified in the Bidding Requirements, Contract Forms andConditions of Contract, unless approved by the Engineer or designatedrepresentative in conjunction with the Water and Wastewater Utility StandardProducts Committee. The Standard Product List current at the time of planapproval will govern.

A. Welded Steel

Welded steel grates and frames shall conform to the number; size, dimensionsand details indicated on the Drawings and shall be welded into an assembly inaccordance with those details. Steel shall conform to the requirements ofASTM A 36/A 36M, “Specification for Structural Steel”.

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B. Castings

Castings, whether Carbon-Steel, Gray Cast Iron or Ductile Iron shall conformto the shape and dimensions indicated on the Drawings and shall be cleansubstantial castings, free from sand or blowholes or other defects. Surfaces ofthe castings shall be free from burnt on sand and shall be reasonably smooth.Runners, risers, fins and other cast on pieces shall be removed from thecastings and such areas ground smooth. Bearing surfaces between manholerings and covers or grates and frames shall be cast or machined with suchprecision that uniform bearing shall be provided throughout the perimeterarea of contact. Pairs of machined castings shall be matchmarked to facilitatesubsequent identification at installation with the exception of water andwastewater manhole and valve castings. These manhole and valve castingsshall be fabricated with such draft, tolerances, bolt hole spacing, etc., that allrings and covers of a particular type or class are interchangeable and match-marking will not be required.

Steel castings shall conform to ASTM A 27/27M, “Specifications for SteelCastings, Carbon, for General Application”. Grade 70-36 (480-250) shall befurnished unless otherwise specified on the Drawings.

Cast iron castings shall conform to ASTM A 48, “Specification for Gray IronCastings”, Class 30.

Ductile Iron castings shall conform to ASTM A 536, “Specification forDuctile Iron Castings”. Grade 60-40-18 (415-275-125) shall be used unlessotherwise indicated on the Drawings.

C. Manhole Cover Riser Rings

Height-adjustment inserts for wastewater manhole rings, which are used forraising standard manhole covers, shall be those models listed in Water andWastewater Standard Products List item QPL WW-330.

D. Nuts and Bolts

Nuts and bolts shall be hex head 5/8” x 2.5” (16 mm x 63.5 mm) #11National Coarse Thread, Type 316 stainless steel. For bolted manhole covers,a thin film of an approved "Anti-freeze" compound, approved by theEngineer or designated representative, shall be applied to all bolts.

E. Mortar

Unless otherwise specified or approved by the Engineer or designatedrepresentative, the mortar for bedding castings shall consist of one (1) partPortland cement and three (3) parts sand and sufficient water to provide thedesired consistency. The gradation of the fine aggregate shall meet therequirements for Grade No. 1, Section 421.2.(5) of TxDOT SpecificationItem No. 421, "Portland Cement Concrete”.

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SS503.4 Construction Methods

Frames, grates, rings and covers shall be constructed of the specified materials inaccordance with the details indicated on the Drawings or in the City of AustinStandard Details. The Frames, grates, rings and covers shall be placed carefully tothe lines or grades indicated on the Drawings or as directed by the Engineer ordesignated representative.

All welding shall conform to the requirements of the ANSI/AWS StructuralWelding Code D1.1. Welded frames, grates, rings and covers shall be given 1coat of a commercial grade red lead oil paint and 2 coats of commercial gradealuminum paint. All coats shall be a minimum of 1.5 mils (0.4 mm), dry.

Painting of gray iron castings will not be required, except when used inconjunction with structural steel shapes.

SS503.5 Measurement and Payment

Frames, grates, rings and covers will not be measured and payment for furnishingall materials, tools, equipment, labor and incidentals to complete the Work willbe included in the Bid Items identified in TxDOT Special Specification, “Waterand Wastewater Utilities” which constitute the complete structures.

End

12. SPECIFIED Cross Reference MaterialsSpecial Specification Item Number SS503, "Frames, Grates, Rings and Covers"

Texas Department of Transportation: Standard Specifications for Constructionand Maintenance of Highways, Streets, and BridgesDesignation Description Item No. 431 Portland Cement Concrete

City of Austin Water and Wastewater Standard Products ListDesignation DescriptionQPL WW-330 Manhole Cover Riser Rings for raising City of Austin

Standard Manhole Covers

American Society for Testing Materials (ASTM)Designation DescriptionA36/A36M Specification for Structural SteelA27/A27M Specification for Steel Castings, Carbon, for GeneralApplicationA48 Specification for Gray Iron CastingsA536 Specification for Ductile Iron Castings

ANSI/AWS

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Designation DescriptionCode D 1.1 Structural Welding Code

13. RELATED Cross Reference MaterialsSpecial Specification Item Number SS503, "Frames, Grates, Rings and Covers"

City of Austin Special SpecificationsDesignation DescriptionItem No. SS504 Adjusting Structures/Water MetersItem No. SS510 PipeItem No. SS506 Manholes

City of Austin Standard DetailsDesignation DescriptionNo. 503S-1 457mm (18") Cover and FrameNo. 503S-2S Storm Sewer Manhole Ring and 610 mm (24") CoverNo. 503S-2W Sanitary Sewer Manhole Ring and 610 mm (24") CoverNo. 503S-3S Bolted Storm Sewer Manhole Ring and 610 mm (24") CoverNo. 503S-3W Bolted Sanitary Sewer Manhole Ring and 610 mm (24") CoverNo. 503S-4S Storm Sewer Manhole Ring and 813 mm (32") CoverNo. 503S-4W Sanitary Sewer Manhole Ring and 813 mm (32") CoverNo. 503S-5S Bolted Storm Sewer Manhole Ring and 813 mm (32") CoverNo. 503S-5W Watertight Manhole Ring and 813 mm (32") CoverNo. 506S-2 Major Manhole AdjustmentNo. 506S-11 Storm Sewer Manhole Details

TxDOT SpecificationsDesignation DescriptionItem 421 Portland Cement Concrete

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Item No. SS504Adjusting and Relocating Structures/Water Meters

SS504.1 Description

This item shall govern the removal and replacement of surfacing, furnishing ofmaterials, adjusting, replacing, and/or repositioning existing structures, valveboxes, pull boxes, survey monument boxes and water meters in accordance withthese specifications to the locations or elevations indicated on the Drawings oras directed by the Engineer or designated representative. This item shall alsogovern any pumping, bailing and drainage required to complete the Work andTxDOT Specification Item No. 402, "Trench Safety Systems" for trench wallswhen indicated on the Drawings.

This specification is applicable for projects or work involving either inch-poundor SI units. Within the text the inch-pound units are given preference followedby SI units shown within parentheses

SS504.2 Submittals

The submittal requirements of this specification item include:

A. Aggregate type, gradations and physical characteristics for the Portlandcement concrete mix.

B. Proposed proportioning of materials for the mortar mix.C. Type structures and proposed adjustment technique (lowering, raising,

lateral displacement).D. Type structure, repair technique and materials to be furnished (new

replacement or reuse of existing) Type of mixing plant and associatedequipage including chart indicating the calibration of each cold bin

SS504.3 Materials

Precast reinforced concrete rings and castings in good condition, which areremoved from the structures to be adjusted, may be reused with the writtenapproval of the Engineer or designated representative. Additional materialsrequired shall conform to the details indicated on the Drawings.

A. Portland Cement Concrete

The Portland cement concrete shall be Class A conforming to TxDOTSpecification Item No. 421, "Portland Cement Concrete".

B. Mortar

Unless otherwise specified or approved by the Engineer or designatedrepresentative, the mortar for bedding castings shall consist of one (1) partPortland cement and three (3) parts sand, by volume based on drymaterials. Sufficient water will be added to provide the desired

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consistency. The gradation of the fine aggregate shall meet therequirements for Grade No. 1, Section 421.2.(5) of TxDOT SpecificationItem No. 421, "Portland Cement Concrete”.

C. Water Meters

Where encroachment into Private Property is called for on Drawings, theCity of Austin shall supply new water meters equal to the size and type ofthe water meter that will be replaced. Contractor is to contact the City ofAustin Meter Shop at (512) 322-2769, 72 hours prior to operations.

SS504.4 Construction Methods

All adjustments shall be completed prior to the placement of the final surface.

Pull box and valve box components scheduled for reuse shall be carefullyremoved and the contact areas shall be cleaned of all mortar, concrete, greaseand sealing compounds. Any items broken in the process of removal andcleaning shall be replaced in kind by the Contractor at its own expense.

If the adjustment involves slight lowering or raising a valve box or surveymonument box, the outside shell of a slip or screw casing shall be excavated toits full length and adjusted to the proposed grade. Pipe castings shall beexcavated to the depth required to cut from or weld a section to the casing asmay be needed to adjust the ring to the proposed elevation. The ring shall bewelded to the casing prior to pouring concrete around the casing.

If the adjustment involves a vertical (lowering or raising) or a horizontalreassignment of a water meter and the property owner's cut off valve, this workshall be completed in accordance with Standard Installation Details included inthe City of Austin Standard Details Series (501S-1, 504S-3, 511S-13A, 511S-13B, etc.).

In cases where encroachment into Private Property is called for on Drawings,new water meters shall be obtained prior to work on the lot to minimize timethat Property Owner will be without water service.

A certified Plumber will have to connect property owner’s line and valve withnew meter or be present to inspect and approve of work done by Contractor.

After the adjustments have been completed and cured, structures within thepaved area shall be paved as indicated on the Drawings.

SS504.5 Measurement and Payment

Work performed and materials furnished as prescribed by this item as indicatedshall be measured and paid by appropriate bid items in accordance with TxDOTSpecial Specification, “Water and Wastewater Utilities” Sections entitled“Measurement” and “Payment.”

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End

SPECIFIC CROSS REFERENCE MATERIALSSpecial Specification SS504, “Adjusting Structures/Water Meters”

Texas Department of Transportation Standard Specifications for Construction andMaintenance of Highways, Streets, and Bridges

Designation DescriptionItem No. 421 Portland Cement ConcreteItem No. 402 Trench Safety Systems

City of Austin Standard DetailsDesignation DescriptionNo. 501S-1 Encasement Detail W/ Casing SpacersNo. 504S-3 Gas Valve Casing AdjustmentNo. 511S-13A Water Valve Box Adjustment to Grade w/ Full Depth

ConcreteNo. 511S-13B Water Valve Box Adjustment to Grade w/ Concrete and

HMAC

RELATED CROSS REFERENCE MATERIALSSpecification 504S, “Adjusting Structures”

City of Austin Standard Specifications

Designation DescriptionItem No. 501S Jacking or BoringItem No. 502S TunnelingItem No. 503S Frames, Grates, Rings and CoversItem No. 505S Concrete Encasement and Encasement PipeItem No. 507S BulkheadsItem No. 508S Miscellaneous Structures and Appurtenances

City of Austin Special SpecificationDesignation DescriptionItem No. SS511 Water Valves

City of Austin Standard DetailsDesignation DescriptionNo. 1100S-1 Casting AdjustmentNo. 725S-1 Monument, Type A Survey Identification MarkerNo. 725S-2 Monument, Type B Survey Identification MarkerNo. 725S-3 Monument, Type C Survey Identification MarkerNo. 725S-7 Survey Identification Marker Non-Traffic Construction DetailNo. 725S-10 Survey Identification Marker Roadway Construction Detail

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No. 725S-11 Adjustable Valve Box For Survey Monument

Texas Department of Transportation: Standard Specifications for Construction andMaintenance of Highways, Streets, and BridgesDesignation DescriptionItem No.476 Jacking, Boring or Tunneling Pipe

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Item No. SS505Concrete Encasement and Encasement Pipe

SS505.1 Description

This item shall govern the furnishing of materials and the methods forconstructing Portland cement concrete encasement or for placing encasementpipe, in trenches. (Placement of encasement pipe by Jacking or Boring iscovered by City of Austin Special Specification Item No. SS501.)

This specification is applicable for projects or work involving either inch-pound or SI units. Within the text and accompanying tables, the inch-poundunits are given preference followed by SI units shown within parentheses.

14. SS505.2 Submittals

The submittal requirements of this specification item for concrete encasementinclude:

A. Concrete mix design

The submittal requirements of this specification item for encasement pipeinclude:

A. Type of encasement pipe, construction methods and sequence,

B. Bedding materials

C. Casing spacers, and

D. Boot or seal wrap.

SS505.3 Materials

A. Portland Cement Concrete

The Portland cement concrete shall conform to Class B Concrete, TxDOTSpecification Item No. 421, "Portland Cement Concrete".

B. Encasement Pipe

Portland Cement concrete pipe shall conform to ASTM C-76, Class III orbetter.

Steel Pipe shall conform to ASTM A134 with a minimum thickness of 3/8inch (9.5 mm) for pipe with a diameter of 16 inches (400 mm) and greater.

C. Casing Spacers

Casing spacers shall conform to SPL WW-575.

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D. Boots or Seal WrapBoots and seal wrap for sealing the ends of the encasement pipe shall be of atype and material approved by the Engineer.

SS505.4 Construction Methods

When indicated on the Drawings or acceptable to Engineer or designatedrepresentative, concrete encasement shall be placed to protect the pipe. Pipe orbedding shall not be placed where:

(a) the top of the pipe would have less than 30 inches (60 mm) of cover,(b) the ground water invades the trench, or(c) the trench bottom is of unstable material.

If either of these conditions is encountered, the Engineer or designatedrepresentative shall be notified and may direct the Contractor to:

(a) encase the pipe with concrete,(b) change pipe material, or(c) use a higher strength class of pipe.

Concrete encasement shall extend from 6 inches (150 mm) below to 6 inches(150 mm) above the outer projections of the pipe over the entire width of thetrench.

When indicated on the Drawings or acceptable to Engineer or designatedrepresentative, the pipe shall be placed in encasement pipe in accordance withCity of Austin Standard No. 501S-1. The encasement pipe shall be placed in atrench according to Sections 510.3(4), (5), (7), (8), (9), (11), (12) and (13) ofCity of Austin Special Specification No. 510, “Pipe.” Encasement pipe shall beinstalled in bedding according to Section 510.3(14) and shall be backfilledaccording to Section 510.3(25). After placement of the carrier pipe iscomplete, the ends of the encasement pipe shall be sealed using a boot or sealwrap, designed specifically for that purpose and approved by the Engineer.

SS505. 5 Measurement and Payment

Work performed and materials furnished as prescribed by this item will bemeasured and paid by the appropriate unit bid price identified in TxDOTSpecial Specification, entitled “Water and Wastewater Utilities”.

End

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SPECIFIC Cross Reference MaterialsSpecial Specification Item No. SS505, :”Encasement and Encasement Pipe"

Texas Department of Transportation: Standard Specification for Constructionand Maintenance of Highways, Streets, and BridgesDesignation DescriptionItem 421 Portland Cement Concrete

City of Austin Special SpecificationDesignation DescriptionItem SS510 Pipe

City of Austin Standard DetailsDesignation DescriptionDetail 501S -1 Encasement Detail w/ Casing Spacers

American Society for Testing and Materials (ASTM)Designation DescriptionA-134 Specification for Pipe, Steel, Electric-Fusion

(Arc)-Welded (Sizes NPS 16 and Over)C-76/C-76M Specification for Reinforced Concrete Culvert,

Storm Drain, and Sewer Pipe

RELATED Cross Reference MaterialsSpecial Specification Item No. SS505, :“Encasement and Encasement Pipe"

TxDOT SpecificationsDesignation DescriptionItem 421 Portland Cement ConcreteSection 421.9 Quality of ConcreteSection 421.2(8) Mortar and GroutItem No. 501S Jacking or Boring PipeItem No. 502S TunnelingItem No. 506S ManholesItem No. 507S BulkheadsItem No. 593S Concrete Retards

City of Austin Standard Specification ItemsDesignation DescriptionSection 510.2(8)(c) Concrete pipeSection 510.2(8)(m) Steel Pipe

City of Austin Water and Wastewater Standard Products (SPL)Designation DescriptionWW-575 Casing Spacers

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Item No. SS506Manholes

SS506.1 Description

This item shall govern construction of manholes, complete in place, and thematerials used therein, including excavation, installation, backfilling and surfacerestoration. It shall also include furnishing and installing rings, covers, andappurtenances, as well as any pumping and drainage necessary to complete thework. Wastewater manholes shall be ‘acceptance tested’ by the Contractor. Thisitem shall also govern abandonment of existing manholes that will be retired dueto this project.

The Contractor shall submit descriptive information and evidence that thematerials and equipment the Contractor proposes for incorporation in the Workare of the kind and quality that satisfies the specified functions and quality asspecified or presented in the Drawings. The City of Austin Water andWastewater Utility Standard Products Lists (SPLs) form a part of theSpecifications for the Work. Contractors may, when appropriate, elect to useproducts from the SPL; however, submittal to the Engineer or designatedrepresentative shall still be required. If the Contractor elects to use anymaterials from these lists, each product shall be completely and clearlyidentified by its corresponding SPL number, when making the productsubmittal. This will expedite the review process in which the Engineer ordesignated representative, and, if necessary, the Water and Wastewater UtilityStandard Products Committee, decide whether the products meet the Contractrequirements and the specific use foreseen by the Engineer or designatedrepresentative in the design of this engineered Project.

The purpose of the SPLs is to expedite the review by the Engineer or designatedrepresentative and, if necessary, the City of Austin Water and WastewaterUtility Standard Products Committee, of Contractor’s product submittal. TheSPLs should not be interpreted as being a pre-approved list of productsnecessarily meeting the requirements for a given construction Project. Itemscontained in the SPL cannot be substituted for items shown on the Drawings, orcalled for in the specifications, or specified in the Bidding Requirements,Contract Forms and Conditions of Contract, unless approved by the Engineer ordesignated representative in conjunction with the City of Austin Water andWastewater Utility Standard Products Committee. The Standard Product Listcurrent at the time of plan approval will govern.

This specification is applicable for projects or work involving either SI or inch-pound units. Within the text and accompanying tables, the SI units are givenpreference followed by inch-pound units shown within parentheses.

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SS506.2 Submittals

The submittal requirements of this specification item include:

A. Type, size and manufacturer of manhole (diameter of water or wastewatermanhole), structure (precast, cast in place; Standard, Tee, etc), andmaterials and equipment to be furnished (brick, concrete, seals, rings,covers, etc.)

B. Aggregate types, gradations and physical characteristics for the Portlandcement concrete mix.

C. Proposed proportioning of materials for the mortar mix.

D. Proposed Acceptance testing procedure and associated test equipment andmaterials Type structures and proposed adjustment technique (lowering,raising, lateral displacement).

Submittal of test Records is required and shall include as a minimum thefollowing items. The test records shall also be included as part of the Projectrecords turned in with the acceptance package.

Name of the manhole manufacturerInterior surface coating type and application method for Wastewater ManholesModel and manufacturer of vacuum testerDate tested/date re-testedPassed/failed and state what was done to correct the problemTest Method UsedLocation/station of manholePrecast/cast-in- place bottomAny repairs made to the joints.

SS506.3 Materials and Components

A. Concrete and Cement Stabilized Sand

All concrete shall conform to TxDOT Specification Item No. 421,"Portland Cement Concrete”. The cast in place concrete shall be TxDOTdefined Class A, and the precast concrete manhole base sections, risersections and appurtenances shall conform to the requirements of ASTMC478/C478M, “Standard Specification for Precast Reinforced ConcreteManhole” with TxDOT defined Class A concrete. All interior surfaces ofwastewater manholes shall receive a coating by an application methodacceptable to the Engineer or designated representative or shall beotherwise acceptably protected from the acidic effects of municipalwastewater. Concrete for backfill of overexcavated areas shall be TxDOTdefined Class A or Class D as indicated on the Drawings. Cementstabilized sand for bedding, backfilling, or abandoning manholes whenindicated or required on the Drawings, shall contain 2 bags of PortlandCement per cubic yard (112 kilograms of Portland cement per cubic

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meter). The sand shall meet the requirements for "Fine Aggregate" inSection 421.2(5) of TxDOT Specification Item No. 421, "Portland CementConcrete".

B. Mortar

The mortar shall be composed of one part Portland cement, one partmasonry cement (or 1/4 part hydrated lime), and sand equal to 2-1/2 to 3times the sum of the volumes of the cements and lime used. The sandshall meet the requirements for "Fine Aggregate" as given in Section421.2(5) of TxDOT Specification Item No. 421 "Portland CementConcrete".

C. Reinforcement

The reinforcing steel shall conform to the requirements of TxDOTSpecification Item No. 440, “Reinforcing Steel”. Secondary, non-structural steel in cast-in-place stormwater manholes may be replaced bycollated fibrillated polypropylene fibers, if approved by the Engineer ordesignated representative.

D. Brick

The brick for ring adjustment courses and for stormwater manholes shallbe of first quality, sound, hard burned, perfectly shaped brick conformingto the requirements of ASTM C 62, Grade SW, or concrete brick meetingthe requirements of ASTM C 55, Grade N-1.

E. Rings and Covers

Rings and covers shall conform to the requirements of City of AustinSpecial Specification Item No. SS503, “Frames, Grates, Rings andCovers”.

1. Replacement Rings and Covers, 24 in. (610 mm) Diameter Lids.

This ring and cover shall be used for the replacement of broken ringsand covers, minor manhole adjustment, or as otherwise directed by theEngineer or designated representative.

2. Rings and Covers, 32 in. (813 mm) Diameter Lids.

This ring and cover shall be used for all new manhole construction,except as otherwise directed by the Engineer or designatedrepresentative.

F. Bulkheads.

Bulkheads shall meet the requirements of City of Austin SpecialSpecification Item No. SS507 “Bulkheads”

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G. Precast Base Sections, Riser Sections, and Cones.

Precast concrete base sections, riser sections, and cones shall conform tothe requirements of ASTM C 478. The width of the invert shall bespecifically sized for the connecting pipes. Inverts shall be “U” shapedwith a minimum depth of three fourths of the largest pipe diameter. Theinvert shall have a minimum difference of 0.10 feet (30 mm) between theinlet and outlet. Where lines enter the manhole up to 24 inches (610 mm))above the flowline of the outlet, the invert shall be filleted to preventsplashing and solids deposition. A drop pipe shall be provided for a sewerentering a manhole at more than 24 inches (610 mm) above the flowline ofthe outlet.

Joints for wastewater base sections, riser sections, and cones shall conformto the requirements of ASTM C 443. Additionally, joint dimensions for48-inch (1.22 meters) inside diameter wastewater manhole sections andcones shall comply with City of Austin Standard Detail No. 506S-12, “ O-Ring Joint Detail Precast Manhole Section” or City of Austin StandardDetail No. 506S-13, “Wedge Seal Joint Detail, Precast Manhole Section”.Precast bases for 48 inch (1.22 meters) inside diameter manholes shallhave preformed inverts. Inserts acceptable to the Engineer or designatedrepresentative shall be embedded in the concrete wall of the manholesections to facilitate handling; however, through-wall holes for lifting willnot be permitted. Any voids between the pipe and boot shall be filled tothe springline with a product recommended by the manhole manufacturerto prevent solids collection.

H. Precast Junction Boxes.

Precast junction boxes shall be allowed only where indicated on theDrawings or acceptable to the Engineer or designated representative.Joints for wastewater junction boxes shall conform to the requirements ofASTM C 443.

I. Pipe-to-Manhole/Junction Box Assemblies

Precast bases and precast junction boxes shall have flexible, resilient andnon-corrosive boot connectors or ring waterstops acceptable to theEngineer or designated representative conforming to the requirements ofASTM C 923 on all wastewater pipe connections.

J. Precast Flat-Slab Transition/Junction Box Lids.

Precast slab transitions and lids shall be designed to safely resist pressuresresulting from loads which might result from any combination of forcesimposed by an HS-20 loading as defined by the American Association ofState Highway and Transportation Officials (AASHTO). The joints ofprecast slab transitions and of lids for wastewater applications shallconform to the requirements of ASTM C443.

K. Precast-Prefabricated Tee Manholes.

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Tee manholes shall be allowed only where indicated on the Drawings or asdirected by the Engineer or designated representative. The main pipesection shall conform to the requirements of City of Austin SpecialSpecification Item No. SS510, “Pipe”. The vertical manhole portion (tee)above the main pipe shall conform to the requirements of the precastcomponents.

The manhole tee shall have a minimum inside diameter of 48 inches (1.22meters) and shall rise vertically centered or tangent to the main pipe, asindicated on the Drawings or as directed by the Engineer or designatedrepresentative. An access hole less than 48-inches (1.22 meters) indiameter shall be cut into the main pipe to allow a ledge for support ofaccess ladders. Unless otherwise specified on the Drawings, the main pipeportion of the tee manhole shall be paid subsidiary to the unit tee manholeprice.

L. Precast Grade Rings

Rings shall be reinforced Class A or I concrete.

1. Precast Grade Rings, 24-1/2 inches (622 mm) Inside Diameter:

This adjustment ring shall be used only for adjusting existing manholeswith 24 inch (610 mm) lids and for Wastewater Access Device. Insideto outside diameter dimension of ring shall be 6 inches (152 mm) witha thickness of 3 inches to 6 inches (76 mm to 152 mm).

2. Precast Grade Rings, 35 inches (889 mm) Inside Diameter:

This adjustment ring shall be used for all new manhole constructionwith 32 inches (813 mm) lids. Inside to outside diameter dimension ofring shall be 6 inches (152 mm)) with a thickness of 4 inches to 6inches (102 mm to 152 mm).

M. New Manhole Construction and Minor Manhole Adjustment:

New manhole construction and minor manhole adjustments shall beperformed as indicated on City of Austin Standard Detail 506S-4, “NewManhole Construction and Minor Manhole Adjustment”, and shall consistof adding precast reinforced concrete rings to adjust the manhole to finalgrade.

For new manhole construction, the maximum vertical allowable ringadjustment, including the depth of the ring casting, shall be limited to 18inches (450 mm). For adjustments of existing manholes that fall within thelimits of overlay and street reconstruction projects, the maximum verticalallowable, including the depth of the ring casting, shall be limited to twofeet (600 mm). All other existing manholes shall have a maximumallowable ring adjustment, including the depth of the ring casting, of onefoot (300 mm). Any adjustment that will exceed these requirements shallbe accomplished as indicated on City of Austin Standard Detail 506S-2,

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"Major Manhole Adjustment" and as described below in subsection (N).All manholes not located in paved areas shall have bolted covers.

N. Major Manhole Adjustment:

Any adjustment that exceeds the requirements of subsection (M) MinorManhole Adjustments, shall be accomplished as indicated on City ofAustin Standard Detail 506S-2, “Major Manhole Adjustment”, and shallconsist of any combination of removing the concrete rings, and/or themanhole cone section, and/or the straight riser section of the manhole inorder to bring the manhole to final grade. All manholes not located inpaved areas shall have bolted covers.

O. Waterproofing Joint Materials.

O-rings and wedge seals for the joints of all wastewater manholes, and forstormwater manholes when indicated on the Drawings, shall conform tothe requirements of ASTM C443. Cold applied preformed plastic gasketsfor stormwater manholes shall be as specified in City of Austin SpecialSpecification Item No. SS510, “Pipe”. The connections betweenreinforced concrete wastewater manhole structures and pipes shall meetthe requirements of ASTM C923.

SS506.4 Construction

All manholes shall have a minimum inside diameter of 48 inches (1.22 meters).Manhole base section or junction box dimension shall be appropriately increasedto accommodate all converging pipe. A minimum horizontal clearance of 12inches (300 mm) shall be maintained between adjacent pipes. Pipe ends withinthe base section or junction box walls shall not be relied upon to supportoverlying manhole dead and live load weights. All wastewater branchconnections to new or existing mains shall be made at manholes with theinfluent pipe crown installed at the elevation of the effluent pipe crown. Wherelines enter the manhole up to 24 inches (600 mm) above the flowline of theoutlet, the invert shall be sloped upward to receive the flow, thus preventingsplashing or solids deposition. Where the springline of an influent pipe is 24inches (600 mm) or more above the springline of the effluent pipe, a dropmanhole shall be used. Construction of extensions to existing systems shallrequire placement of bulkheads at locations indicated or directed by theEngineer or designated representative. Unless otherwise indicated on theDrawings, stormwater manholes shall have eccentric cones; wastewatermanholes shall have concentric cones, except on manholes over large mainswhere an eccentric cone shall be situated to provide access to an invert ledge.Eccentric cones may be used where conflicts with other utilities dictate. Flat-slab tops may be used where clearance problems exist [see SS506.3(J) above].

Manholes shall be founded at the established elevations on uniformly stablesubgrade. Unstable subgrade shall be over-excavated a minimum of 12 inches(300 mm) and replaced with a material acceptable to the Engineer or designated

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representative. Precast base units shall be founded and leveled on a 6 inch (150mm) coarse aggregate bedding. A pipe section with a prefabricated tee manholeand half the length of the adjoining pipe sections on each side shall be foundedon a minimum of 6 inch (150 mm) unreinforced Class A concrete (TxDOTSpecification Item No. 421, “Portland Cement Concrete”). The cast-in-placeconcrete cradle shall be placed against undisturbed trench walls up to the pipe'sspringline.

All adjustments shall be completed prior to the placement of the final surface.

Manhole components to be reused shall be carefully removed and the contactareas shall be cleaned of all mortar, concrete, grease and sealing compounds.Any items broken in the process of removal and cleaning shall be replaced inkind by the Contractor at its expense.

If the adjustment involves lowering the top of a manhole, a sufficient depth ofprecast concrete rings or brick courses shall be removed to permitreconstruction. The mortar shall be cleaned from the top surface remaining inplace and from all brick or concrete rings to be reused and the manhole rebuilt tothe required elevation. The manhole ring and cover shall then be installed withthe top surface conforming to the proposed grade.

If the adjustment involves raising the elevation of the top of the manhole inaccordance with SS506.3 (M), "New Manhole Construction and Minor ManholeAdjustment", the top of brick or concrete ring shall be cleaned and built upvertically to the new elevation, using new or salvaged concrete rings or bricksand the ring and cover installed with the top surface conforming to the proposedgrade.

Cast-in-place foundations shall have a minimum depth of 12 inches (300 mm) atthe invert flowline. The widths of all manhole inverts shall be specifically sizedfor the connecting pipes. Inverts shall be “U” shaped with a minimum depth ofthree fourths of the largest pipe diameter. The invert shall have a minimum fallof 0.10 of a foot (30 mm) between the inlet and outlet. The lowermost risersection may be set in the Portland cement concrete, while still green, after whichthe foundation shall be cured a minimum of 24 hours prior to proceeding withconstruction of the manhole up to 12 feet (3 2/3 meters) in depth. Thefoundation shall be cured an additional 24 hours prior to continuing constructionabove the 12 foot (3 2/3 meters) level. Manhole depth shall be measured fromthe invert flowline to the finish surface elevation.

Wastewater manholes having cast in place foundations may be constructed overexisting wastewater pipes, except polyvinyl chloride (PVC), and the top half ofthe pipe removed to facilitate invert construction. The manhole bottom shallrise from the springline elevation of the pipe, approximately one inch for each12 inches (80 mm per meter) of run (8%). Wastewater manholes with lineslarger than 18 inches (450 mm) shall require precast bases; manholesconstructed over in-service mains however, may be built on cast-in-place

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foundations if the flow cannot be interrupted. Precast and cast-in-placewastewater junction boxes shall be allowed only where indicated on theDrawings or acceptable to the Engineer or designated representative. The floorsof stormwater manholes also, shall rise outwardly from the springline on a slopeof 1:12 or 80 mm per meter (8%).

Wastewater lines, except reinforced concrete pipe, set in cast-in-placefoundations, shall require a waterstop seal or gasket acceptable to the Engineer ordesignated representative around the outside perimeter of the pipe. It shall beapproximately centered under the manhole section wall.

Cast-in-place stormwater manholes, junction boxes and flat-slab transitions shallbe reinforced, Class A concrete (TxDOT Specification Item No. 421, "PortlandCement Concrete"). All structural concrete work shall conform to TxDOTSpecification Item No. 420, “Concrete Structures”. Forms will be required for allcast-in-place walls above the foundation. Where the surrounding material can betrimmed to a smooth vertical face, outside forms may be omitted.

Backfilling for manholes shall conform to the density requirements of City ofAustin Special Specification Item No. SS510, “Pipe”. Manhole construction inroadways may be staged to facilitate base construction. Manholes constructed tointerim elevations shall be covered with steel plates of sufficient thickness tosupport vehicular traffic. Steel plates on wastewater manholes shall be set inmortar to minimize inflow. Manholes shall be completed to finish elevation priorto placement of the roadway's finish surface. The excavation for completion ofmanhole construction shall be backfilled with cement stabilized sand with 2 sacksof cement per cubic yard (112 kilograms of cement per cubic meter) up to thebottom of Portland Cement pavement slabs or to within 2 inches (50 mm) offinish elevation of asphaltic concrete pavements. The cement stabilized sandshall be a minimum of 12 inches (300 mm) thick.

After rings and covers are set to grade, the inside and outside of the concreterings shall be wiped with mortar so placed as to form a durable water-tight jointsmooth and even with the manhole cone section. No grouting shall be performedwhen the atmospheric temperature is at or below 40°F (5oC), and whennecessary, because of a sudden drop in temperature, joints shall be protectedagainst freezing for at least 24 hours.

For this project, after all new wastewater mains are placed in service, existingmanholes within project limits, connected to now abandoned wastewater mains,shall have their top 18” removed. The manholes will be filled with 2-sack leanmix. The abandoned mains to these manholes shall be plugged prior to fillingoperations.

SS506.5 Acceptance Testing of Wastewater Manholes:

Manholes shall be tested separately and independently of the wastewater lines.

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A. Test by the Vacuum Method:

A vacuum test shall be performed by the Contractor prior to backfillingthose manholes that fall within the right-of-way that require detouring ofvehicular traffic. A second vacuum test will not be required after backfillingand compaction is complete unless there is evidence that the manhole hasbeen damaged or disturbed subsequent to the initial vacuum test.

For manhole installations which do not require detouring of vehicular traffic,the vacuum method is recommended and may be used by the Contractorprior to backfilling the manhole to insure proper installation so that defectsmay be located and repaired; however, a vacuum test shall be performedafter backfilling, and compaction are complete. Testing after backfill andcompaction are complete will be the basis for acceptance of the manhole.

1. Equipment:

a) The manhole vacuum tester shall be a device approved for use by theEngineer or designated representative.

b) Pipe sealing plugs shall have a load resisting capacity equal to orgreater than that required for the size of the connected pipe to besealed.

2. Procedures - applicable to new 4'-0" (1.22 meter) diameter manholes.

a) Manhole section interiors shall be carefully inspected; units found tohave through-wall lift holes, or any penetration of the interior surfaceby inserts provided to facilitate handling, will not be accepted.Coating shall be applied after the testing unless coating is appliedbefore installation or unless it is applied at the factory. All lift holesand exterior joints shall be plugged with an acceptable non-shrinkgrout. No grout shall be placed in horizontal joints.

b) After cleaning the interior surfaces of the manhole, the Contractorshall place and inflate pneumatic plugs in all of the connecting pipesto isolate the manhole; sealing pressure within the plugs shall be asrecommended by the plug manufacturer. Plugs and the ends of pipesconnected by flexible boots-shall be blocked to prevent theirmovement during the vacuum test.

c). The vacuum test head shall be placed on the top of the cone sectionor, inside of the top of the manhole cone section, and the compressionseal band inflated to the pressure recommended by its manufacturer.The vacuum pump shall be connected to the outlet port with the valveopen. When a vacuum of 10 inches (254 mm) of mercury [(-5 psig){-35 kPa}] has been attained, the valve shall be closed and the timenoted. Tampering with the test equipment will not be allowed.

d) The manhole shall have passed the test if the vacuum does not dropbelow 9 inches (229 mm) of mercury [(-4.5 psig){-31 kPa}] within

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three (3) minutes of the time the valve was closed. The actualvacuum shall be recorded at the end of the three (3) minutes duringwhich the valve was closed.

e). When the standard vacuum test cannot be performed because of designor material constraints (examples: T-Type manholes, T-Lock Liners,or other reasons acceptable to the Engineer or designatedrepresentative), testing of individual joints shall be performed asdirected by the Engineer or designated representative.

B. Test by the Exfiltration Method:

At the discretion of the Engineer or designated representative, the Contractormay substitute the Exfiltration Method of testing for the Vacuum testdescribed in Section SS506.5. A above. This method may only be used whenground water is not present. If ground water is present a Vacuum Test shallbe used unless otherwise directed by the Engineer or designatedrepresentative. All backfilling and compaction shall be completed prior tothe commencement of testing.

The procedures for the test shall include the following:

1. Manhole section interiors shall be carefully inspected; units found to havethrough-wall lift holes, or any penetration of the interior surface by insertsprovided to facilitate handling, will not be accepted. Coating shall beapplied after the testing unless coating is applied before field assembly, orat the factory. All lift holes and exterior joints shall be plugged with anacceptable non-shrink grout. No grout shall be placed in horizontal joints.

2. After cleaning the interior surface of the manhole, the Contractor shallplace and inflate pneumatic plugs in all of the connecting pipes to isolatethe manhole; sealing pressure within the plugs shall be as recommendedby the plug manufacturer.

3. Concrete manholes shall be filled with water or otherwise thoroughlywetted for a period of 24 hours prior to testing.

4. At the start of the test, the manhole shall be filled to the top with water.The test time shall be 1 hour (60 minutes). The Construction Inspectormust be present for observation during the entire time of the test.Permissible loss of water in the 1 hour test time is 0.025 gallons perdiameter foot, per foot of manhole depth (1.0 liter per diameter in meters,per meter of manhole depth). For a 4 foot (1.22 meter) diameter manhole,this quantity converts to a maximum permissible drop in the water level(from the top of the manhole cone) of 0.05 inches per foot (4 mm permeter) of manhole depth or 0.5 inches for a 10 foot (12.5 mm for a 3meter) deep manhole.

C. Failure to Pass the Test - Records of Tests.

If the manhole fails to pass the initial test method as described in (A) Test bythe Vacuum Method and, if allowed, (B) Test by the Exfiltration Method, or

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if visible groundwater leakage into the manhole is observed, the Contractorshall locate the leak, if necessary by disassembly of the manhole. TheContractor shall check the gaskets and replace them if necessary. TheContractor may re-lubricate the joints and re-assemble the manhole, or theContractor may install an acceptable exterior joint sealing product (see Cityof Austin Standard Products List Item SPL WW-146A) on all joints and thenretest the manhole. If any manhole fails the vacuum and/or exfiltration testtwice, the Contractor shall consider replacing that manhole. If the Contractorchooses to attempt to repair that manhole, the manhole must be retested untilit passes. In no case shall cold applied preformed plastic gaskets be used forrepair. Records of all manhole testing shall be made available to the Engineeror designated representative at the close of each working day, or as otherwisedirected by the Engineer or designated representative. Any damaged orvisually defective products, or any products out of acceptable tolerance shallbe removed from the site.

D. Inspection.

The Engineer or designated representative shall make a visual inspection ofeach manhole after it has passed the testing requirements and is considered tobe in its final condition. The inspection shall determine the completeness ofthe manhole; any defects shall be corrected to the satisfaction of Engineer ordesignated representative.

SS506.6 Measurement and Payment:

Work performed and materials furnished as prescribed by this item will bemeasured and paid by the appropriate unit bid price identified in TxDOT SpecialSpecification, entitled “Water and Wastewater Utilities.”

End

SPECIFIC Cross Reference MaterialsStandard Specification Item No. 506S, "Manholes"

Texas Department of Transportation Standard Specifications for Constructionand Maintenance of Highways, Streets, and BridgesDesignation DescriptionItem 420 Concrete StructuresItem 421 Portland Cement ConcreteItem 440 Reinforcing Steel

City of Austin Special SpecificationsDesignation DescriptionItem SS503 Frames, Grates, Rings and CoversItem SS504 Adjusting StructuresItem SS507 BulkheadsItem SS510 Pipe

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City of Austin Water and Wastewater Utility DocumentsDesignation DescriptionSPL WW-146A Manhole Seals, Plastic, Watertight

City of Austin Standard DetailsDesignation Description

15. 506S-2 Major Manhole Adjustment506S-4 New Manhole Construction and Minor Manhole Adjustment506S-12 O-Ring Joint Detail, Precast Manhole Section506S-13 Wedge Seal Joint Detail, Precast Manhole Section

American Society for Testing and Materials (ASTM)Designation DescriptionASTM C 55 Specification for Concrete Building BrickASTM C478/C478M Standard Specification for Precast Concrete ManholeASTM C443/C443M Specification for Joints for Circular Concrete

Sewer and Culvert Pipe, Using Rubber GasketsASTM C923/C923M Specification for Resilient Connectors Between Reinforced

Concrete Manhole Structures Pipes

RELATED Cross Reference Materials

City of Austin Utilities Criteria ManualDesignation DescriptionSection 2 Water and Wastewater Design Criteria

City of Austin Standard DetailsDesignation Description

16. 1100S-1 Casting Adjustments503S-4S Storm Sewer Manhole Ring and 813 mm (32”) Cover503S-4W Sanitary Sewer Manhole Ring and 813 mm (32”) Cover503S-5S Bolted Storm Sewer Manhole Ring and 813 mm (32”) Cover

17. 503S-5W Watertight 18. 506S-1 Manhole Invert Plan

506S-5 Typical Box Manhole 750 mm (30”) and Larger Pipe506S-7 Precast Manhole with Drop Inlet506S-8 Precast Manhole with Drop Inlet on Precast Base506S-9 Precast Manhole On Cast-In-Place Foundation506S-10 Wastewater Manhole on Precast Base506S-11 Storm Sewer Manhole Details

City of Austin Water and Wastewater Utility DocumentsDesignation DescriptionSPL Standard Products Lists (SPL)

American Society for Testing and Materials (ASTM)

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Designation DescriptionASTM C 62 Specification for Building Brick (Solid Units Made from Clay or

Shale)ASTM C478/C478M Specification for Precast Reinforced Concrete Manhole Sections

American Association of State Highway and Transportation Officials (AASHTO)Designation DescriptionM306 Standard Specifications for Drainage Structure Castings

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Item No. SS507Bulkheads

SS507.1 Description

This item shall govern furnishing and installing plywood or end caps as atemporary utility plug at locations indicated on the Drawings or as directedby the Engineer or designated representative. The work will be placed inconjunction with installation of a pipe where a continuation of the utilitysystem will be performed later.

This specification is applicable for projects or work involving either inch-pound or SI units. Within the text, the inch-pound units are given preferencefollowed by SI units shown within parentheses.

SS507.2 Submittals

The submittal requirements of this specification item include the type (wood,plastic, rubber, etc.) and application (pipe characteristics and location) ofbulkheads.

SS507.3 Material

Plywood shall be construction grade, 3/4 inch (19 mm) thick and need not benew or treated. End caps may be plastic, vitrified clay pipe, rubber orconcrete.

SS507.4 Construction MethodsAfter installation of the utility requiring temporary bulkheading, an end capor a section of plywood, having dimensions at least 6 inches (150 mm) inexcess of the outside pipe diameter shall be attached to the exposed bell orspigot and backfilled immediately after installation. Care shall be exercisedto prevent the backfill material from entering the pipe.

Bulkheads used with staged construction shall be sound, reasonably free ofknots and warps and have a 3 inch (75 mm) nominal thickness.

507S.5 Measurement and Payment

Bulkheading will not be measured and paid for separately but shall beconsidered subsidiary to bid items related to TxDOT Special Specification,“Water and Wastewater Utilities”.

END

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RELATED Cross Reference MaterialsSpecial Specification Item No. 507S, "Bulkheads"

City of Austin Utilities Criteria ManualDesignation DescriptionSection 2 Water and Wastewater Design Criteria

City of Austin Special SpecificationDesignation DescriptionItem No. SS506 ManholesItem No. SS510 Pipe

City of Austin Standard DetailsDesignation Description

19. 506S-1 Manhole Invert Plan506S-5 Typical Box Manhole 750 mm (30”) and Larger Pipe506S-7 Precast Manhole with Drop Inlet506S-8 Precast Manhole with Drop Inlet on Precast Base506S-9 Precast Manhole On Cast-In-Place Foundation506S-10 Wastewater Manhole on Precast Base506S-11 Storm Sewer Manhole Details

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Item No. SS510Pipe

SS510.1 DescriptionThis item shall consist of furnishing and installing all pipe and/or materials forconstructing pipe mains, sewers, laterals, stubs, inlet leads, service connectionsand culverts, including all applicable Work such as excavating, bedding,jointing, backfilling materials, tests, concrete trench cap, concrete cap andencasement, etc., prescribed under this item in accordance with the provisions ofthe Edwards Aquifer Protection Ordinance, when applicable, and City of AustinUtility Criteria Manual, Section 5, "Cuts in Public Right of Way". The pipe shallbe of the sizes, types, class and dimensions indicated or as designated by theE/A and shall include all joints or connections to new or existing mains, pipes,sewers, manholes, inlets, structures, etc., as may be required to complete theWork in accordance with specifications and published standard practices of thetrade associations for the material specified and to the lines and gradesindicated. This item shall include any pumping, bailing, drainage and TxDOTSpecification Item No. 402, "Trench Safety Systems" for trench walls, whenindicated or applicable. Unless otherwise provided, this item shall consist of theremoval and disposition of trees, stumps and other obstructions, old structures orportions thereof such as house foundations, old sewers, masonry or concretewalls, the plugging of the ends of abandoned piped utilities cut and left in placeand the restoration of existing utilities damaged in the process of excavation,cutting and restoration of pavement and base courses, the furnishing and placingof select bedding, backfilling and cement or lime stabilized backfill, the haulingand disposition of surplus materials, bridging of trenches and other provisionsfor maintenance of traffic or access as indicated. Also, any and all pot-holing forexisting utility elevation verification.

SS510.2 MaterialsThe Contractor shall submit descriptive information and evidence that thematerials and equipment the Contractor proposes for incorporation into theWork is of the kind and quality that satisfies the specified functions and quality.Water and Wastewater Utility Standard Products Lists (SPL) form a part ofthe Specifications. Contractors may, when appropriate, elect to use productsfrom the SPL; however, submittal to the E/A is still required. Should theContractor elect to use any materials from these lists, each product shall becompletely and clearly identified by its corresponding SPL number whenmaking the product submittal. This will expedite the review process in which theE/A, and, if necessary, the Water and Wastewater Utility Standard ProductsCommittee, decides whether the products meet the Contract requirements andthe specific use foreseen by the E/A in the design of this engineered Project. Thepurpose of the SPL’s is to expedite review, by the E/A and, if necessary, theWater and Wastewater Utility Standard Products Committee, of Contractorproduct submittals. The SPL’s should not be interpreted as being a pre-approvedlist of products necessarily meeting the requirements for a given constructionProject. Items contained in the SPL cannot be substituted for items shown on the

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Drawings, or called for in the specifications, or specified in the BiddingRequirements, Contract Forms and Conditions of Contract, unless approved bythe E/A in conjunction with the Water and Wastewater Utility Standard ProductsCommittee. The Standard Product List current at the time of plan approval willgovern.

(1) Concrete

Concrete shall conform to TxDOT Specification Item No. 421, "PortlandCement Concrete".

(2) Coarse Aggregate

Coarse aggregate shall conform to TxDOT Specification Item No. 421,"Portland Cement Concrete" or as follows:

(a) Pipe Bedding Stone

Pipe bedding stone shall be clean gravel, crushed gravel or crushedlimestone, free of mud, clay, vegetation or other debris, conforming toASTM C 33 for stone quality. Size gradation shall conform to ASTMC-33 No. 57 or No. 67 or the following Table:

SIEVE SIZE % RETAINED BYWEIGHT

1-1/2" 01" 0-10

1/2" 40-85#4 90-100#8 95-100

(b) Foundation Rock

Foundation rock shall be well graded coarse aggregate ranging in sizefrom 2 to 8 inches.

(c) Flexible Base

Flexible base shall conform to TxDOT Specification Item No. 247,"Flexible Base".

(3) Fine Aggregate

(a) Concrete and Mortar Sand

Fine aggregate shall conform to Item No. 421, "Portland CementConcrete".

(b) Bedding Sand

Sand for use as pipe bedding shall be clean, granular and homogeneousmaterial composed mainly of mineral matter, free of mud, silt, clay

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lumps or clods, vegetation or debris. The material removed bydecantation TxDOT Test Method Tex-406-A, plus the weight of anyclay lumps, shall not exceed 4.5 percent by weight.

The resistivity shall not be less than 3000 ohms-cm as determined byTxDOT Test Method Tex-129-E. Size gradation of sand for beddingshall be as follows:

GRADATION TABLESIEVE SIZE % RETAINED BY WEIGHT

1/4" 0#60 75-100#100 95-100

(c) Stone Screenings

Stone screenings shall be free of mud, clay, vegetation or other debris,and shall conform to the following Table:

SIEVE SIZE % PASSING3/8" 100

No. 4 95 to 100No. 8 80 to 100No. 16 50 to 85No. 30 25 to 60No. 50 10 to 30No. 100 2 to 10

All screenings shall be the result of a rock crushing operation.

(4) Controlled Low Strength Material

Controlled Low Strength Material (CLSM) shall conform to Item SS402,"Controlled Low Strength Material”.

(5) Pea Gravel

Pea gravel bedding shall be clean washed material, hard and insoluble inwater, free of mud, clay, silt, vegetation or other debris. Stone quality shallmeet ASTM C 33. Size gradation shall be as follows:

SIEVE SIZE % RETAINED BYWEIGHT

3/4" 01/2" 0-251/4" 90-100

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(6) Select Backfill or Borrow

This material shall consist of borrow or suitable material excavated from thetrench. It shall be free of stones or rocks over 8 inches and shall have aplasticity index of less than 20. The moisture content at the time ofcompaction shall be within 2 percent of optimum as determined by TxDOTTest Method Tex-114-E. Sandy loam borrow will not be allowed unlessshown on the Drawings or authorized by the E/A.

All suitable materials from excavation operations not required for backfillingthe trench may be placed in embankments, if applicable. All unsuitablematerials that cannot be made suitable shall be considered surplus excavatedmaterials as described in 510.3(13). The Contractor may, if approved by theengineer, modify unsuitable materials to make them suitable for use.Modification may include drying, removal or crushing of over-size material,and lime or cement treatment.

(7) Cement Stabilized Backfill

When indicated or directed by the E/A, all backfill shall be with cement-stabilized backfill rather than the usual materials. Unless otherwiseindicated, cement stabilized backfill material shall consist of a mixture ofthe dry constituents described for TxDOT Specification Item 421 Class DConcrete. The cement and aggregates shall be thoroughly dry mixed withno water added to the mixture except as may be directed by the E/A.

(8) Pipe

General

Fire line leads and fire hydrant leads shall be ductile iron. Domestic waterservices shall not be supplied from fire service leads, unless the domesticand fire connections are on separately valved branches with an approvedbackflow prevention device in the fire service branch. All wastewater forcemains shall be constructed of ductile iron pipe Pressure Class 250 minimumfor pipe greater than 12 inch size and Pressure Class 350 for pipe 12 inchsize and smaller. Wastewater pipe shall be in accordance with Water andWastewater Utility’s Standard Products List SPL WW-534 and shall have acorrosion resistant interior lining acceptable to the Owner.

All water pipe within utility easements on private property shall be DuctileIron Pipe, Pressure Class 350 minimum for pipe 12 inch size and smallerand Pressure Class 250 minimum for pipe greater than 12 inch size wrappedas indicated. For sizes over 24 inches, Concrete Pressure Pipe, steel cylindertype, conforming to the requirements of AWWA C-301 will be acceptable.

There may be no service connections to Concrete Pressure Pipe installed inutility easements on private property. Approved service clamps or saddlesshall be used when tapping ductile iron pipe 12 inch size and smaller. Allservice tubing (3/4 inch thru 2 inches) installed in utility easements on

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private property shall be 150 psi annealed seamless Type K copper tubingwith no sweat or soldered joints.

The quality of materials, the process of manufacture and the finished pipeshall be subject to inspection and approval by the E/A at the pipemanufacturing plant and at the project site prior to and during installation.All water distribution pipe and fittings shall be listed in the Fire ProtectionEquipment Directory published by the Underwriter's Laboratories, Inc., orshall be Factory Mutual approved for fire service.

(a) Reserved

(b) Iron Pipe

Iron pipe shall be ductile iron pipe meeting all requirements of standardsas follows:-For push-on and mechanical joint pipe: AWWA C-151

-For flanged pipe: AWWA C-115

Barrels shall have a nominal thickness required by Table 1 of AWWA C-115, whichthickness corresponds to Special Class 53 in sizes through 54 inch, and Class 350 in60 and 64 inch sizes. Flanges shall be ductile iron (gray iron is not acceptable); theyshall be as shown in ANSI/AWWA C115/A21.15 and shall conform to dimensionsshown in Table 2 and Figure 1 of AWWA C115. These flanges are the same in allrespects as flanges shown in ANSI/AWWA C110/A21.10 for fittings and arestandard for all flanges used with pipe, valve, and equipment units in the City ofAustin water distribution and wastewater force main systems. Flanges shall befabricated and attached to the pipe barrels by U.S. fabricators using flanges and pipebarrels of U.S. manufacture. If fabrication is to be by other than the pipe barrelmanufacturer, a complete product submittal and approval by the Water andWastewater Utility will be required. Additionally, such fabricator shall furnishcertification that each fabricated joint has been satisfactorily tested hydrostatically ata minimum pressure of 300 psi.

-Linings and Coating:Interior surfaces of all iron water pipe shall be cement-mortar lined and sealcoated as required by AWWA C104. Interior surfaces of all iron wastewaterline and force main pipe shall be coated with a non-corrosive lining material asindicated on Water and Wastewater Utility’s Standard Products List SPL WW-534. Pipe exteriors shall be coated as required by the applicable pipespecification. The type and brand of interior lining shall be clearly marked onthe outside of the pipe and fittings. Except as authorized by the E/A, only onetype and brand of pipe lining shall be used on a given project.

Except as described above for flanged pipe (Thickness Class 53) andwhere not otherwise indicated, ductile iron pipe shall be minimum Class250 as defined by ANSI/AWWA C150/A21.50-current; all ductile ironpipe and flanges shall meet the following minimum physicalrequirements:

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-Grade 60-42-10:-Minimum tensile strength: 60,000 psi (414 mPa).-Minimum yield strength: 42,000 psi (290 mPa).-Minimum elongation: 10 percent.

The flanges for AWWA C115 pipe may be also be made from:

Grade 70-50-05:-Minimum tensile strength: 70,000 pi (483 map).-Minimum yield strength: 50,000 pi (345 mPa).-Minimum elongation: 5 percent.

1. Ductile Iron Fittings:

Fittings shall be push-on, flanged ormechanical joint as indicated or approved and shall meet allrequirements of standards as follows:

-Sizes 4 inch through 24 inch: AWWA C-110 or AWWA C-153

-Sizes larger than 24 inch: AWWA C-110.

-Lining and Coating: Interior surfaces or all iron water pipefittings shall be lined with cement- mortar and seal coated asrequired by AWWA C104. Interior surfaces of all ironwastewater and force main fittings shall be coated with a non-corrosive lining material acceptable to Owner. Fitting exteriorsshall be coated as required by the applicable pipe specification.

2. Joint Materials

Gaskets for mechanical joints shall conform to ANSI/AWWAA21.11/C-111.

Joining of slipjoint iron pipe shall, without exception, be accomplishedwith the natural or synthetic rubber gaskets of the manufacturer of thatparticular pipe being used. A joint lubricant shall be used andapplicable recommendations of the manufacturer shall be followed.

Gaskets for flanged joints shall be continuous full face gaskets, of 1/8inch minimum thickness of natural or synthetic rubber, cloth-reinforced rubber or neoprene material, preferably of deformed crosssection design and shall meet all applicable requirements ofANSI/AWWA A21.11/C-111 for gaskets. They shall be manufacturedby, or satisfy all recommendations of, the manufacturer of thepipe/fittings being used and be fabricated for use with Class 125 ANSIB16.1 flanges.

Tee-head bolts, nuts and washers for mechanical joints shall be highstrength, low alloy, corrosion resistant steel stock equal to "COR-TENA" having UNC Class 2 rolled threads or alloyed ductile iron

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conforming to ASTM A 536; either shall be fabricated in accordancewith ANSI/AWWA A21.11/C-111.

Hex head bolts and nuts shall satisfy the chemical and mechanicalrequirements of ASTM A449 SAE Grade 5 plain, and shall befabricated in accordance with ASTM B 18.2 with UNC Class 2 rolledthreads.

Either Tee-Head or Hex-Head bolts, nuts and washers as required, shallbe protected with bonded fluoro-polymer corrosion resistant coatingwhere specifically required by the E/A.

All threaded fasteners shall be marked with a readily visible symbolcast, forged or stamped on each nut and bolt, which will identify thefastener material and grade. The producer and the supplier shallprovide adequate literature to facilitate such identification; paintedmarkings are not acceptable.

3. Polyethylene Film Wrap

All iron pipe, fittings and accessories shall be wrapped with standard 8mil (minimum) low density polyethylene film or 4-mil (minimum)cross laminated high-density polyethylene conforming to AWWA C-105, with all edges overlapped and taped securely with duct tape toprovide a continuous wrap to prevent contact between the piping andthe surrounding backfill. Repair all punctures of the polyethylene,including those caused in the placement of bedding aggregates, withduct tape to restore the continuous protective wrap before backfilling.

4. Marking

Each pipe joint and fitting shall be marked as required by theapplicable AWWA specification. This includes in all cases:Manufacturer's identification, Country where cast, year of casting, and"DUCTILE" or "DI". Barrels of flanged pipe shall show thicknessclass; others shall show pressure class. The flanges of pipe sectionsshall be stamped with the fabricators identification; fittings shall showpressure rating, the nominal diameter of openings and the number ofdegrees for bends. Painted markings are not acceptable.

(c) Concrete

1. General

Pipe shall conform to ASTM C 76 for Circular Pipe. Concrete pipesmaller than 12 inches in diameter shall conform to ASTM C 14,Extra Strength. All pipe shall be machine made or cast by a processwhich will provide uniform placement of the concrete in the formand compaction by mechanical devices which will assure a denseconcrete. Concrete shall be mixed in a central batch plant or otherapproved batching facility from which the quality and uniformity of

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the concrete can be assured. Transit mixed concrete shall not beacceptable for use in precast pipe. The pipe shall be Class III or theclass indicated. Storm sewer pipe shall be of the tongue and grooveor 0-ring joint design. Wastewater pipe shall be of the 0-ring jointdesign; it shall be acceptably lined for corrosion protection.

2. Marking

Each joint of pipe shall be marked with the pipe class, the date ofmanufacture, the manufacturer's name or trade mark, diameter ofpipe and orientation, if required.

Pipe marking shall be waterproof and conform to ASTM C 76.

3. Minimum Age for Shipment

Pipe shall be considered ready for shipment when it conforms to thetests specified in ASTM C 76.

4. Joint Materials

When constructing storm sewers, the Contractor shall have the optionof making joints with either of the following materials:

a. Mortar

Mortar for joints shall meet the requirements set forth below in"Mortar".

b. Cold Applied Preformed Plastic Gaskets

Cold Applied Plastic Gaskets shall be suitable for sealing joints oftongue and groove concrete pipe. The gasket sealing the joint shallbe produced from blends of refined hydrocarbon resins andplasticizing compounds reinforced with inert mineral filler andshall contain no solvents, irritating fumes or obnoxious odors. Thegasket joint sealer shall not depend on oxidizing, evaporating orchemical action for its adhesive or cohesive strength and shall besupplied in extruded rope form of suitable cross section. The sizeof the plastic gasket joint sealer shall be in accordance with themanufacturer's recommendations and sufficient to obtain squeeze-out around the joint. The gasket joint sealer shall be protected by asuitable removable wrapper that may be removed longitudinallywithout disturbing the joint sealer to facilitate application.

The chemical composition of the gasket joint sealing compound asshipped shall meet the following requirements:

Composition (% by weight) Test Method Typical AnalysisBitumen (petroleum plastic content) ASTM D 4 50-70

Ash-inert Mineral Water Tex-526-C 30-50

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Volatile Matter (at 325 F) Tex-506-C 2.0 Maximum

The gasket joint sealing compound when immersed for 30 days atambient room temperature separately in 5 percent solution of causticpotash, a mixture of 5 percent hydrochloric acid, a 5 percent solution ofsulfuric acid and a saturated H2S solution shall show no visibledeterioration.

The physical properties of the gasket joint sealing compound as shippedshall meet the following requirements:

Typical AnalysisProperty

TestMethod Minimum Maximum

Specific Gravity at 77 F ASTM D 71 1.20 1.35Ductility at 77F (cm) Minimum Tex-503-C 5.0Softening point Tex-505-C 275 FPenetration: 32 F (300 g) 60 sec Tex-502-C 75 77 F (150 g) 5 sec Tex-502-C 50 120 115 F (150 g) 5 sec Tex-502-C 150Flashpoint C.O.C. F Tex-504-C 600 FFire Point C.O.C. F Tex-504-C 625 F

When constructing wastewater lines, the Contractor shall use 0-ringgasket joints conforming to ASTM C 443. Just before making ajoint, the ends of the pipe shall be clean, dry, free of blisters orforeign matter and shall be wire brushed. For O-ring joints, thegasket and the inside surface of the bell shall be lubricated with alight film of soft vegetable soap compound to facilitate assembly ofthe joint. The rubber O-ring gasket shall be stretched uniformly in thejoint. Wedge seal type ("Forsheda" pre-lubricated) gaskets may beused if joint details submitted are approved; installation of suchgaskets shall be in strict accordance with the manufacturer'srecommendations, and shall be the sole element depended upon tomake the joint flexible and watertight.

In wastewater lines no horizontal or vertical angles in the alignment ofpipes shall be permitted unless indicated. The spigot shall be centered inthe bell, the pipe pushed uniformly home and brought into truealignment. Bedding material shall be placed and tamped against pipe tosecure the joint.

5. Bends

When horizontal or vertical angles in the alignment of storm sewersare indicated, the bend or angle shall be constructed by cutting on a

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bias one or both pipes as may be required for the alignment indicated.The pipe cut shall be sufficiently long to allow exposing thereinforcement, which shall be bent, welded and incorporated into thepipe bend and reinforced concrete collar to maintain the structuralintegrity. The collar shall be 6 inches minimum, reinforced with #4bars on a 1 foot center both directions. Builder's hardware cloth maybe used on the outside of the joint to aid in holding cementingmaterials in place. Plywood, fiberboard or other materials placed onthe inside of the pipe as formwork shall be removed as soon as thejoint materials have obtained initial set, after which the inside surfaceof the pipe joint shall be finished smooth and true to the line andgrade established. The Contractor may use prefabricated bendsmeeting the specification requirements in lieu of field fabricatedbends. All bends shall be watertight, have a smooth flow line and beequal or greater in strength to the adjacent pipe.

Horizontal or vertical changes in alignment in wastewater lines shallbe accomplished by use of manholes. With the E/A’s approval,horizontal changes in alignment may be made by the "JointDeflection" method. Joint deflection is limited by regulations of theTexas Natural Resource Conservation Commission (TNRCC) to 80percent of the maximum recommended by the manufacturer; suchdeflection may not exceed 5 degrees at any joint. Changes inalignment using pipe flexure shall not be allowed.

6. Sulfide and Corrosion Control

All concrete pipe used for wastewater installations shall be protectedfrom sulfide and corrosion damage by using limestone aggregate.

(d) Concrete Steel Cylinder (CSC) Pipe

1. General Requirements

The Contractor shall submit to the E/A for approval along with otherrequired data a tabulated layout schedule with reference to thestationing and grade lines to be used.

The manufacturer shall furnish all fittings and special piecesrequired for closures, bends, branches, manholes, air valves,blowoffs and connections to main line valves and other fittings asindicated.

Each pipe length, fitting and special joint shall have plainly markedon the bell end of the pipe, the head condition for which it isdesigned. In addition, marking shall be required to indicate thelocation of each pipe length or special joint in the line and suchmarkings will be referenced to the layout schedules and drawingsand submitted for approval.

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Concrete steel cylinder fittings shall be tested as required by theapplicable AWWA Standards.

2. Design and Inspection

Where not otherwise indicated, concrete steel cylinder pipe shall beClass 150, designed to withstand a vacuum of not less than 28 feet ofwater. Valve reducers, tees and outlets from a pipe run shall be designedand fabricated so that all stresses are carried by the steel forming thefitting or outlet.

Concrete steel cylinder pipe shall meet one of the followingspecifications:

AWWA C-301 - Any SizeAWWA C-303 - 24 inch maximum size

All pipe flanges shall conform to AWWA C-207, requirements forstandard steel flanges of pressure classes corresponding to the pipeclass.

Pipe to be installed in a tunnel or encasement shall be manufacturedwith 1 inch thick by 24 inch wide skid bands of mechanically impactedmortar in addition to the normal coating.

All concrete steel cylinder fittings shall be constructed of steel plate ofadequate strength to withstand both internal pressure and externalloading. Rod reinforcing shall not be used to figure the required steelarea. The fittings shall have a concrete lining and 1 inch minimumcoating of cement mortar, except that centrifugally spun lining need notbe reinforced.

Minimum lining thickness shall be 1/2 inch for 16 inch pipe and 3/4inch for sizes larger than 16 inch pipe. Where it is impractical to placesuch concrete protection on interior surfaces of small outlets, 2 coats of"Bitumastic Tank Solution" shall be applied.

No fitting shall be made by cutting of standard pipe, except that outletsof less than 75 percent of the pipe diameter may be placed in a standardpipe. Beveled spigots may be placed on standard pipe.

3. Joint Materials

Joints shall be of the rubber gasket type conforming to the applicablestandards. The inside and outside recesses between the bell and spigotshall be completely filled with Cement Grout in accordance with thepipe manufacturer's recommendations. Grout materials for jointing suchpipe, unless otherwise indicated, shall be as described herein.

(e) In Place Pipe Rehabilitation

1. In Place Sliplining With or Without Pipe Destruction/Replacement.

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This item shall consist of installing a high density polyethylene pipe, byuse of a pipe insertion machine into an existing line.

a. Material Requirements

The polyethylene pipe shall meet the following specifications:

ASTM F 714Plastic Pipe Institute PE3408

Unless otherwise specified, the Contractor shall furnish thepolyethylene pipe in accordance with the following table:

Depth of Cover in Feet SDR of Pipe0 - 16 17

Greater than 16 11

b. Functional Requirements

The polyethylene pipe shall be assembled and joined at the siteusing the thermal butt fusion method. All equipment and proceduresshall be in strict compliance with the manufacturer'srecommendations. Fusing shall be accomplished by personnelcertified as fusion technicians by a manufacturer of polyethylenepipe and/or fusing equipment.

The complete joint shall be in true alignment and have a uniformdouble roll back bead resulting from the use of proper temperatureand pressure. The joint shall be allowed adequate cooling timebefore removal of pressure. Joints shall be made smooth on theinside by removal of the projecting weld bead using appropriateequipment; maximum projection of the weld bead on the exterior ofthe pipe shall be approximately 3/16 inch. The fused joint shall bewatertight and shall have a tensile strength equal to that of the pipe.All joints shall be subject to acceptance by the E/A or his/herrepresentative prior to placement. All defective joints shall be cutout and replaced.

Any section of the pipe with a gash, abrasion, nick or scar greater indepth than 10 percent of the wall thickness, or containingconcentrated ridges, discolorization, excessive spot roughness,pitting, variable wall thickness, or any other defect of manufacturingor handling as determined by the E/A or his/her representative, shallbe discarded and removed from the site.

Terminal sections of pipe that are joined within the insertion pitshall be connected with a full circle pipe repair clamp with aminimum length of one and one half times the nominal inside pipediameter, in accordance with Water and Wastewater Utility’s

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Standard Products List SPL No. 271. The butt gap between pipeends shall not exceed 1/10 of the nominal inside diameter of thepipe.

c. Installation Procedure

The Contractor shall carry out his operations in strict accordancewith all OSHA and manufacturer's safety requirements.

The Contractor shall provide for the flow of water and wastewateraround the section or sections of pipe designated for rehabilitationincluding active services in the rehabilitation section. The bypassshall be made by plugging the line at an existing upstream manholeor adjacent system. The pump and bypass lines shall be of adequatecapacity and size to handle the flow. The Contractor shall take allnecessary steps to prevent flooding of any private property and shallbe liable for damages incurred by the flooding. No sewage or watershall be allowed to drain into earthen sump pits.

New polyethylene pipe shall be inserted immediately behind theexpansion and insertion equipment in accordance with themanufacturer's procedures. The expansion and insertion equipmentshall be equipped with all controls necessary to place the pipe onproper line and grade according to the Drawings.

The Contractor shall install all pulleys, rollers, bumpers, alignment controldevices and other equipment required to protect existing manholes and toprotect the pipe from damage during installation.

Lubrication may be used as recommended by the pipe manufacturer.Under no circumstances shall the pipe be stressed beyond its elastic limit.

All active service connections shall be identified by video inspection orother means and connected to the new main in accordance with the plandetails.

Upon commencement, insertion, from manhole to manhole, shall becontinuous without interruption except as approved by the E/A.

The installed pipe shall be allowed the manufacturer's recommendedamount of time to provide for complete shrinkage or relaxation of the pipeprior to any connection of service lines, sealing of the annular space wherethe pipe enters the manhole, or backfilling of the insertion pit. Sufficientexcess length of pipe shall be allowed to provide for this shrinkage.

The pipe bedding in the insertion pit shall be either pea gravel or pipebedding stone. Bedding and backfill shall conform to the specificationrequirements of Section SS510.3(14) contained herein. All street repairsand pavement replacement shall conform to City of Austin Utility CriteriaManual, Section 5, "Cuts in Public Right of Way".

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The relaxed pipe shall be cut so that it projects 4 inches inside of themanhole and any annular space shall be sealed. Sealing shall be withmaterial approved by the E/A. The sealant shall completely fill the voidbetween the pipe and the manhole wall and shall extend 3 inches beyondthe annulus on the inside wall of the manhole. The sealant shall form asmooth transition from the pipe onto the manhole. The complete joint shallbe uniform and watertight. A concrete invert shall be poured in place andshaped to form a smooth flow channel through the manhole.

2. Cured Resin Pipe Lining

This method of rehabilitation shall consist of the insertion of a resin-impregnated flexible tube into an existing pipe by the inversion methodgiven in ASTM F 1216 or by a comparable approved method.

a. Material Requirements

Certified copies of all test reports on the properties of the selected resin andon the initial structural properties of the CIPP system—and later, on thefield samples from designated inversion lengths as required by Section 8 ofASTM F 1216—shall be submitted to the Owner's E/A.

All testing costs are incidental to, and shall be included in, the unitprice bid for CIPP.

The Cured in Place Pipe (CIPP) system shall have minimum initialstructural properties as follows:

Flexural Strength (ASTM D 790) 4,500 psiTensile Strength (ASTM D 638) 2,500 psiFlexural Modulus (ASTM D790) 250,000 psi

The results of tests by an independent laboratory, of specimens takenby the Contractor as required by Section 8 of ASTM F 1216 and todemonstrate compliance with the above minimum values, shall bemade available to the Owner's E/A at the completion of testing.

b. Installation Procedure

Insertion of a resin-impregnated flexible tube into an existing pipe shallbe by an inversion method as given in ASTM F 1216 and themanufacturer's recommendations.

The Contractor shall carry out his operations in strict accordance withall OSHA and manufacturer's safety requirements.

Measures shall be taken to reduce atmospheric styrene concentration toan acceptable level at all times during the cured in place pipeinstallation procedure. The percent lower explosive limit, temperatureand styrene concentration shall be measured and recorded for eachinversion taken to ensure the following conditions are met:

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Percent Lower Explosive Limit (LEL) shall not exceed 2% using anatmospheric monitor calibrated within at least six (6) months of theday reading is taken. The LEL shall be measured at the top of thedownstream manhole adjacent to the section of pipe being lined.

No process water shall be discharged until cooled to below 100degrees Fahrenheit in accordance with Section 7.1 of ASTM F 1216.

Atmospheric styrene levels shall not exceed 50 ppm as measured bya Drager Tube 67 23 301 Styrene 10/a five feet above and within 3feet downwind of the downstream manhole adjacent to the section ofpipe being lined.

Contractor shall be responsible for satisfactorily resolving customercomplaints involving styrene odors.

Any necessary repairs to the pipe line shall be performed by theContractor. Inspection of pipe line by the Contractor shall be performedby experienced personnel trained in locating breaks, obstacles andservice connections by closed circuit television. The interior of the pipeshall be carefully inspected to determine the location of any conditionswhich may prevent proper installation into the pipe and these conditionsshall be corrected. A video tape and log shall be made by the Contractorand provided to the Owner upon completion of the project.

The Contractor shall provide for the flow of water and wastewater around thesection or sections of pipe designated for rehabilitation, including activeservices in the rehabilitation section. The bypass shall be made by pluggingthe line at an existing upstream manhole and pumping the flow into adownstream manhole or adjacent system. The pump and bypass lines shall beof adequate capacity and size to handle the flow. The Contractor shall take allnecessary steps to prevent flooding of any private property and shall be liablefor any damages incurred by the flooding. No sewage or water shall beallowed to drain into earthen sump pits.

The Contractor shall designate a location where the uncured resin in theoriginal containers and the unimpregnated fiber-felt tube shall be vacuumimpregnated prior to installation. The Contractor shall allow the E/A toinspect the materials and "wet out" procedure. The quantities of the liquidthermosetting materials shall be per manufacturer's standards to provide thewall thickness specified.

Water for the Work shall be metered and furnished by the Contractor inaccordance with Section 01500. The wet out fiber-felt tube shall be insertedthrough an existing manhole or other approved access by means of aninversion process and the application of a hydrostatic head sufficient to fullyextend it to the next designated manhole.

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Any defect which will affect, in the foreseeable future, or warranty period,the integrity or strength of the pipe liner shall be repaired at the Contractor'sexpense, in a manner satisfactory to the E/A.

If, due to broken or misaligned pipe at a manhole wall, the pipe liner fails tomake a tight seal, the Contractor shall apply a seal at that point. The seal shallbe of a resin mixture compatible with pipe liner.

After the pipe liner has been cured in place, and allowed to cool down andnormalize to ambient temperature, the Contractor shall connect new servicesor reconnect existing service piping as designated and identified in theproposal. After the Work is completed, the Contractor shall provide the E/Awith a video tape showing both the before and after conditions including therestored connections.

(f) Polyethylene Tubing

1. General

All polyethylene (PE) tubing shall be high density, high molecular weightplastic tubing meeting ASTM D2737; it shall be pressure rated at 200 psiworking pressure and must bear the National Sanitation Foundation seal ofapproval for potable water service.

When tested for Environmental Stress Cracking, the PE tubing shall notshow any loss of pressure in the 6 specimens tested for 3 hours inaccordance with the requirements of ASTM D 2737 using the test pressureof 400 psi at 73.4 F.

The minimum burst pressure shall be 630 psi at 73.4 F determined inaccordance with ASTM D 1599, latest revision. The time of testing ofeach specimen shall be between 60 and 70 seconds.

The tubing shall not fail, balloon, burst or weep as defined in ASTM D1598, latest revision, when tested in accordance with the SustainedPressure Test Method of ASTM D 2737 but under the following testconditions:

Temperature Time Pressure

73.4 F 1,000 hours 400 psi100 F 1,000 hours 330 psi

2. Markings

Permanent marking on the tubing shall include the following at intervalsof not more than 5 feet:

Nominal tubing size.Type of plastic material, i.e., PE 3408.

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Standard Dimension Ratio (SDR) and pressure rating in psi for waterat 73.4 F (e.g., SDR-9, 200 psi).

ASTM D 2737 designation.Manufacturer's name or trademark, code and seal of approval (NSF

mark) of the National Sanitation Foundation.

3. Tube Size

PE tubing shall be standard copper tube size outside diameter, withStandard Dimension Ratio (SDR) of 9. Standard sizes, dimensions andtolerances shall be as follows:

Nominal Tube Size Outside Diameter, inches Wall Thickness, inches(inches) Average Tolerance Minimum Tolerance

¾ 0.875 ±0.004 0.097 +0.0101 1.125 ±0.005 0.125 +0.012

1 ¼ 1.375 ±0.005 0.153 +0.0151 ½ 1.625 ±0.006 0.181 +0.0182 2.125 ±0.006 0.236 +0.024

(g) Copper Tubing

All copper service tubing shall be annealed seamless Type K water tubemeeting ASTM B88 and rated at 150 psi working pressure. The tubingshall be homogenous throughout and free from cracks, holes, crimping,foreign inclusions or other defects. It shall be uniform in density andother physical properties.

Outside Diameter, inches Wall Thickness, inchesNominal Tube Size,inches Average Tolerance Average Tolerance

3/4 0.875 ± 0.003 0.065 ± 0.00451 1.125 ± 0.0035 0.065 ± 0.0045

1 1/4 1.375 ± 0.004 0.065 ± 0.00451 1/2 1.625 ± 0.0045 0.072 ± 0.005

2 2.125 ± 0.005 0.083 ± 0.007

(h) Service Connection Fittings

All fittings used in customer service connection - tapping mains, connectingmeters, etc. - must be currently listed on the applicable Water and WastewaterStandard Products List (SPL WW-68), or called for in the City of AustinStandard Details (520 - series).

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(i) Brass Goods

All brass valves, couplings, bends, connections, nipples and miscellaneous brasspipe fittings and accessories used in meter connections, service lines, air releasepiping assemblies, and wherever needed in the water distribution system, shallconform to the City of Austin Standards, Water and Wastewater Utility StandardProducts Lists, and AWWA C-800, except as herein modified or supplemented.

Unless otherwise noted, the goods described herein shall be fabricated ofstandard Red Brass (Waterworks Brass) meeting ASTM B62 or B584, alloy83600, consisting of 85 percent copper and 5 percent each of tin, lead and zinc.

Exposed threads shall be covered with plastic caps or sheeting to protect thethreads.

Brass goods of each type and class shall be compatible with other fittings incommon usage for similar purposes. Where not otherwise indicated, all suchmaterials shall meet the following requirements:

Inlet threads of corporation valves shall be AWWA iron pipe (IP) thread (male);outlets of service saddles shall be tapped with AWWA IP thread (female).AWWA IP threads shall conform to ANSI/ASME B1.20.1 as required byAWWA C800 for “General Purpose (Inch) Pipe Threads”. For 3/4” and 1” sizesonly, corporation valve inlet threads, and the internal threads of saddles may bethe AWWA taper thread conforming to AWWA C800 Figure 1 and Table 6.External threads of corporation valve inlet must be compatible with internalthreads of the service saddle.

Connections of all new tubing, and of tubing repairs wherever possible, shall beby flared fittings. Flare connections - and compression connections whenpermitted - shall be designed to provide a seal and to retain the tubing, withoutslippage, at a working water pressure of 150 psig.

Flanges shall conform to ANSI B16.1, Class 125, as to dimensions, drillings, etc.

Copper tubing, when used, shall be Type K tubing having dimensions andweights given in Table A.1 of AWWA C800.

Brass pipe shall conform to the weights and dimensions for Extra Strongpipe given in Table A.2 of AWWA C800.

All fittings shall be suitable for use at hydrostatic working pressures up to150 psig (hydrostatic testing of installed systems is at 200 psig).

(j) Reserved

(k) Polyvinyl Chloride Water Pipe

1. General

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All polyvinyl chloride (PVC) water pipe shall be of the rigid(UNPLASTICIZED) type and must bear the National SanitationFoundation seal of approval for potable water pipe. Each joint of pipe shallconsist of single continuous extrusion; bells or other components attachedby solvent welding are not acceptable. Pipe shall be pressure rated at 200psi (SDR-14) or 150 psi (SDR-18) as indicated.

Pipe shall have push-on, rubber gasket joints of the bell and spigot typewith thickened integral bells with rubber gasket joints. The wall thicknessof each pipe bell and joint coupling must be greater than the standard pipebarrel thickness. Clearance must be provided in every gasket joint for bothlateral pipe deflection and for linear expansion and contraction. Concretethrust blocking shall be placed behind bends and tees. Concrete supportcradles or blocking shall be required for support of all fire hydrants, valvesand AWWA C110 fittings; such support shall be provided for AWWAC153 fittings when required by the E/A.

2. Applicable Specifications

Except as modified or supplemented herein, PVC pipe shall meet thefollowing standards:

AWWA C-900, SDR 18 or SDR 14 for PVC Pressure Pipe, in 4, 6, 8and 12 inch nominal sizes, having Cast Iron Pipe size outsidediameters.

Fittings used with PVC Pressure pipe shall be AWWA C-110 orAWWA C-153compact ductile iron fittings.

Standard sizes, dimensions and tolerances shall be as follows:

SDR-18 SDR-14Nominal

SizeOutside Diameter,

inchesWall Thickness,

inchesWall Thickness,

inches(inches) Avg. Tolerance Min. Tolerance Min. Tolerance

4 4.800 + 0.009 0.267 + 0.032 0.343 + 0.0416 6.900 + 0.011 0.383 + 0.046 0.493 + 0.0598 9.050 + 0.015 0.503 + 0.060 0.646 + 0.07812 13.200 + 0.015 0.733 + 0.088 0.943 + 0.113

All pipe 4 inches and larger must be approved Underwriter'sLaboratories for use in buried water supply and fire protection systems.

3. Material Requirements

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All pipe and fittings shall be made from clean, virgin, NSF approved, Class12454B PVC. Clean reworked materials generated from the manufacturer'sown production may be used within the current limits of the referencedAWWA C-900.

4. Marking

Permanent marking on each joint of pipe shall include the following atintervals of not more than 5 feet:

Nominal pipe size and OD base (e.g., 4 CIPS).Type of plastic material (e.g., PVC 12454B).Standard Dimension Ratio and the pressure rating in psi for water at 73 F

(e.g., SDR 18, 150 psi).AWWA designation with which the pipe complies (e.g., AWWA C-

900).Manufacturer's name or code and the National Sanitation Foundation

(NSF) mark.

5. Tracer Tape

For all non-metallic pipe, directly above the centerline of the pipe and aminimum of 12 inches below the subgrade, or a minimum of 18 Inches belowfinished grade on areas outside the limits of pavement, shall be placedInductive Tracer Detection Tape in accordance with the manufacturer’srequirements. The tape shall be encased in a protective, inert, plastic jacketand color coded in accordance with APWA Uniform Color Code.

(l) Polyvinyl Chloride (PVC) Pipe (Nonpressure) and Fittings

1. General

Where PVC sewer or wastewater pipe is indicated, it shall conform to ASTM D3034. Cell Class shall be as required by applicable ASTM pipe specification;pipe stiffness shall be 115 psi minimum for pipe to 15" size, or 72 psi minimumfor larger pipe.

2. Joint Material

PVC pipe and fitting shall have elastomeric gasket joints conforming to ASTM D3212; gaskets to ASTM F 477.

3. Pipe Markings

Permanent marking on the pipe shall include the following at intervals of notmore than 5 feet:

Manufacturer's name and/or trademark.Nominal pipe size.PVC cell classification per ASTM D 1784.

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ASTM designation and legend:For pipe 6 inch to 15 inch size: ASTM D 3034, type PSM,SDR-35 PVC Sewer Pipe.

For pipe 18 inch and larger: ASTM F 679. T-1 wall PVCsewer pipe.

4. Fitting Markings

Fittings shall be clearly marked as follows:

Manufacturer's name or trademark,

Nominal size,

The material designation "PVC",

PSM, and the designation, "Specification D3034".

5. Tracer Tape

For all non-metallic pipe, directly above the centerline of the pipe and aminimum of 12 inches below the subgrade, or a minimum of 18 Inchesbelow finished grade on areas outside the limits of pavement, shall beplaced Inductive Tracer Detection Tape in accordance with themanufacturer’s requirements. The tape shall be encased in a protective,inert, plastic jacket and color coded in accordance with APWA UniformColor Code.

(l) Steel Pipe

1. Standard Weight

ASTM A 53, Schedule 40.

2. Extra Heavy Weight

Seamless ASTM A 53, Schedule 80.

3. Encasement Pipe

Welded or Seamless pipepiles ASTM A-252, Grade 2.

4. Fittings

Nipples and fillings extra strong Federal Specification WW-N 351or WW-P 521.

5. Coatings

Black or galvanized as indicated.

(n) Welded Steel Pipe and Fittings for Water-Pipe

1. General Reference Standards Specification.

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Specifications of the American Water Works Association (AWWA)listed below shall apply to this Section.

C-200 Steel Water Pipe 6 inches and larger.C-205 Cement-Mortar Protective Lining and Coating for Steel

Water Pipe, 4 inches and larger, Shop Applied.C-206 Field Welding of Steel Water Pipe.C-207 Steel Pipe Flanges for Waterworks Services, Sizes 4 inches

through 144 inches.C-208 Dimensions for Steel Water Pipe Fittings.C-602 Cement-Mortar Lining of Water Pipelines, 4 inches and

larger in Place.

2. Submittals

Furnish Shop Drawings, product data, design calculations and test reportsas described below:

a. Certified copies of mill tests confirming the type of materialsused in steel plates, mill pipe flanges and bolts and nuts to showcompliance with the requirements of the applicable standards.b. Complete and dimensional working drawings of all pipe layouts.Shop Drawings shall include the grade of material, size, wallthickness of the pipe and fittings, type and location of fittings andthe type and limits of the lining and coating systems of the pipe andfittings.c. Product data to show compliance of all couplings, supports,fittings, coatings and related items.

3. Job Conditions

a. The internal design pressure of all steel pipe and fittings shall be asindicated.

b. The interior of all steel pipe for potable water, 4 inches and larger,shall be cement-mortar lined.

4. Manufacturing

a. Description

Pipe shall comply with AWWA C-200.

(1) Circumferential deflection of all pipe in-place shall not exceed2.0 percent of pipe diameter.

(2) Diameter

Nominal pipe diameter shall be the inside diameter of lining orpipe barrel, unless otherwise designated in Job Conditions.

b. Wall Thickness

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(1) Steel pipe wall thickness shall be designed for the internal andexternal loads specified in this section. The cylinder thicknessneeded to resist internal pressure shall be based on an allowablestress in the steel equal to 1/2 the minimum yield stress of thematerial used.

5. Fittings

a. Welded

Fabricated steel fittings shall be of the same material as pipe andshall comply with AWWA C-208.

6. Flanges

a. Flanges shall comply with the requirements of AWWA C-207, ClassD or Class E. The class shall be based on operating conditions andmating flanges of valves and equipment.

b. Gaskets shall be cloth-inserted rubber, 1/8 inch thick.

c. Flanges shall be flat faced with a serrated finish.

7. Pipe Joints

a. Lap Joints for Field Welding

(1) Lap joints for field welding shall conform to AWWA C-206.This item applies only to pipes 72 inches in diameter and larger.

(2) The bell ends shall be formed by pressing on a hydraulicexpander or a plug die. After forming, the minimum radius ofcurvature of the bell end at any point shall not be less than 15times the thickness of the steel shell. Bell ends shall be formedin a manner to avoid impairment of the physical properties of thesteel shell. Joints shall permit a lap at least 1 1/2 inches whenassembled. The longitudinal or spiral weld on the inside of thebell end and the outside of the spigot end on each section of pipeshall be ground flush with the plate surface. The inside edge ofthe bell and the outside edge of the spigot shall be scarfed orlightly ground to remove the sharp edges or burrs.

b. Bell and Spigot Joints with O-Ring Gasket

(1) Bell and spigot joints with rubber gasket shall conform toAWWA C-200.

(2) The bell and spigot ends shall be so designed that when thejoint is assembled, it will be self-centered and the gasket will beconfined to an annular space in such manner that movement ofthe pipe or hydrostatic pressure cannot displace it. Compressionof the gasket when the joint is completed shall not be dependentupon water pressure in the pipe and shall be adequate to ensure awatertight seal when subjected to the specified conditions of

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service. Bell and spigot ends shall be welded on preformedshapes. The bell and spigot ends shall conform to the reviewedShop Drawings.

8. Interior and Exterior Protective Surface Coatings

a. Exterior Surface to be mortar coated shall conform to AWWAC-205 for shop application and AWWA C-602 for fieldapplication. Pipe materials shall be the product of an organizationwhich has had not less than 5 years successful experiencemanufacturing pipe materials and the design and manufacture ofthe pipe, including all materials, shall be the product of onecompany.

b. All surfaces except as noted in c and d below shall receive shopapplication of mortar lining and coating.

c. Field Welded Joints. After installation, clean, line and coat unlinedor uncoated ends adjacent to welded field joints, including the weldproper, as specified for pipe adjacent to the weld.

d. Machined Surfaces. Shop coat machined surfaces with a rustpreventative compound. After jointing surfaces, remaining exposedsurfaces shall be coated per a) and b) above.

(o) Corrugated Metal Pipe

1. General

Pipe shall be corrugated continuous lock or welded seam helicallycorrugated pipe. Corrugated metal pipe may be galvanized steel,aluminized steel or aluminum conforming to the following:

Galvanized Steel AASHTO M 218Aluminized Steel AASHTO M 274Aluminum AASHTO M 197

Where reference is made herein to gage of metal, the reference is toU.S. Standard Gage for uncoated sheets. Tables in AASHTO M 218and AASHTO M 274 list thickness for coated sheets in inches. TheTables in AASHTO M 197 list thickness in inches for clad aluminumsheets.

Sampling and testing of metal sheets and coils used for corrugatedmetal pipe shall be in accordance with TXDOT Test Method Tex-708-I.

Damaged spelter coating shall be repaired by thoroughly wirebrushing the damaged area and removing all loose, cracked or weld-burned spelter coating. The cleaned area shall be painted with a zincdust-zinc oxide paint conforming to Federal Specifications TT-P641b. Damaged pipe shall be rejected and removed from the project.

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Damaged aluminized coating shall be repaired in accordance with themanufacturer's recommendations.

The following information shall be clearly marked on each section ofpipe:

Thickness and corrugationsTrade Mark of the manufacturerSpecification compliance

2. Fabrication

a. Steel Pipe

Galvanized or aluminized steel pipe shall be full circle or archpipe conforming to AASHTO M 36, Type I or Type II asindicated.

It may be fabricated with circumferential corrugations, lapjoint construction with riveted or spot welded seams or itmay be fabricated with helical corrugations with continuoushelical lock seam or ultra high frequency resistance butt-welded seams.

b. Aluminum Pipe

Pipe shall conform to AASHTO M 196, Type I, circular pipeor Type II, pipe arch as indicated. It may be fabricated withcircumferential corrugations, lap joint construction withriveted or spot welded seams or it may be fabricated withhelical corrugations with a continuous helical lock seam.

Portions of aluminum pipe that are to be in contact with highchloride concrete or metal other than aluminum, shall beinsulated from these materials by a coating of bituminousmaterial. The coating applied to the pipe or pipe arch to provideinsulation between the aluminum and other material shall extenda minimum distance of 1 foot beyond the area of contact.

3. Selection of Gages

The pipe diameter, permissible corrugations and required gaugesfor circular pipe shall be as indicated on the drawings.

For pipe arch, the span, rise, gage, corrugation size and coatingthickness shall be as shown on the drawings. A tolerance of plusor minus 1 inch or 2 percent of equivalent circular diameter,whichever is greater, will be permissible in span and rise, with alldimensions measured from the inside crests of the corrugations.

4. Joint Material

75-169 591509-02

Except as otherwise indicated, coupling bands and other hardware forgalvanized or aluminized steel pipe shall conform to AASHTO M 36for steel pipe and AASHTO M 196 for aluminum pipe. Field jointsfor each type of corrugated metal pipe shall maintain pipe alignmentduring construction and prevent infiltration of soil material duringthe life of the installation.

Coupling bands shall be not more than 3 nominal sheet thicknesslighter than the thickness of the pipe to be connected and in no caselighter than 0.052 inch for steel or 0.048 inch for aluminum.

Coupling bands shall be made of the same base metal and coating(metallic or otherwise) as the pipe.

Coupling bands shall lap equally on each of the pipes beingconnected to form a tightly closed joint after installation.

Pipes furnished with circumferential corrugations shall be fieldjointed with corrugated locking bands. This includes pipe withhelical corrugations, which has reformed circumferentialcorrugations on the ends. The locking bands shall securely fit into atleast one full circumferential corrugation on each of the pipe endsbeing coupled. The minimum width of the corrugated locking bandsshall be as shown below for the corrugation which corresponds to theend circumferential corrugations on the pipes being joined:

10 1/2 inches wide for 2 2/3 inches x 1/2 inch corrugations.

12 inches wide for 3 inches x 1 inch or 5 inches x 1 inchcorrugations.

Helical pipe without circumferential end corrugations will be permittedonly when it is necessary to join a new pipe to an existing pipe, which wasinstalled with no circumferential end corrugations. In this event pipefurnished with helical corrugations at the ends shall be field jointed witheither helically corrugated bands or with bands with projections ordimples. The minimum width of helically corrugated bands shall conformto the following:

12 inches wide for pipe diameters up to and including 72 inches.

14 inches wide for 1 inch deep helical end corrugations.

Bands with projections shall have circumferential rows of projections withone projection for each corrugation. The width of bands with projectionsshall be not less than the following:

12 inches wide for pipe diameters up to and including 72inches. The bands shall have 2 circumferential rows of projections.

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16 1/4 inches wide for pipe diameters of 78 inches and greater. The bands shall have 4 circumferential rows of projections.

Unless otherwise indicated, all bolts for coupling bands shall be 1/2 inchdiameter. Bands 12 inches wide or less shall have a minimum of 2 boltsand bands greater than 12 inches wide shall have a minimum of 3 bolts.

Galvanized bolts may be hot dip galvanized conforming to AASHTOM 232, mechanically galvanized to provide the same requirements asAASHTO M 232 or electro-galvanized per ASTM A 164 Type RS.

5. Additional Coatings or Linings

a. Bituminous Coated

Bituminous Coated pipe or pipe arch shall be as indicated both asto base metal and fabrication and in addition shall be coated insideand out with a bituminous coating which shall meet theperformance requirements set forth herein. The bituminouscoating shall be 99.5 percent soluble in carbon bisulphide. Thepipe shall be uniformly coated inside and out to a minimumthickness of 0.05 inch, measured on the crests of the corrugations.

The bituminous coating shall adhere to the metal tenaciously, shallnot chip off in handling and shall protect the pipe fromdeterioration as evidenced by samples prepared from the coatingmaterial successfully meeting the Shock Test and Flow Test inaccordance with Test Method Tex-522-C.

b. Paved Invert

Where a Paved Invert is indicated, the pipe or pipe arch, inaddition to the fully coated treatment described above, shallreceive additional bituminous material of the samespecification as above, applied to the bottom quarter of thecircumference to form a smooth pavement with a minimumthickness of 1/8 inch above the crests of the corrugations.

c. Cement Lined

(1) General

Except as modified herein, pipe shall conform toAASHTO M 36 for lock seam or welded helicallycorrugated steel pipe. Pipe shall be of full circle and shallbe fabricated with two annular corrugations for purposesof joining pipes together with band couplers. Lock seamsshall develop the seam strength as required in Table 3 ofAASHTO M 36. Concrete lining shall conform to thefollowing:

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CompositionConcrete for the lining shall be composed of cement, fineaggregate and water that are well mixed and of suchconsistency as to produce a dense, homogeneous, non-segregated lining.

CementPortland Cement shall conform to AASHTO M 85.

AggregateAggregates shall conform to AASHTO M 6 except that therequirements for gradation and uniformity of gradation shallnot apply.

MixtureThe aggregates shall be sized, graded, proportioned andthoroughly mixed with such proportions of cement and wateras will produce a homogenous concrete mixture of suchquality that the pipe will conform to the design requirementsindicated. In no case, however, shall the proportions ofPortland Cement, blended cement or Portland Cement pluspozzolanic admixture be less than 470 lb/cu. yd of concrete.

ThicknessThe lining shall have a minimum thickness of 1/8 inch abovethe crest of the corrugations.

Lining ProceduresThe lining shall be plant applied by a machine travelingthrough a stationary pipe. The rate of travel of the machine andthe rate of concrete placement shall be mechanically regulatedso as to produce a homogenous nonsegregated liningthroughout.

Surface FinishThe lining machine shall also mechanically trowel theconcrete lining as the unit moves through the pipe.

CertificationFurnish manufacturer's standard certification of complianceupon request of the purchaser.

JointsPipe shall be joined together with coupling bands made fromsteel sheets to an indicated thickness of 0.064 inch (12 ga.).Coupling bands shall be formed with two corrugations that arespaced to provide seating in the third corrugation of each pipeend without creating more than 1/2 inch ± annular spacebetween pipe ends when joined together.

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Bands shall be drawn together by two 1/2 inch galvanized boltsthrough the use of a bar and strap suitably welded to the band.

When O-ring gaskets are indicated they shall be placed in thefirst corrugation of each pipe and shall be compressed bytightening the coupling band. Rubber O-ring gaskets shallconform to Section 5.9, ASTM C 361.

(2) Causes for Rejection

Pipe shall be subject to rejection on account of failure toconform to any of the indications. Individual sections of pipemay be rejected because of any of the following:

Damaged ends, where such damage would prevent makingsatisfactory joint.Defects that indicate poor workmanship and could not beeasily repaired in the field.Severe dents or bends in the metal itself.If concrete lining is broken out, pipe may be rejected or atthe discretion of the E/A, repaired in the field in accordancewith the manufacturer's recommendation.

Hairline cracks or contraction cracks in the concrete lining are tobe expected and does not constitute cause for rejection.

d. Fiber Bonded

Where fiber bonded pipe is indicated, the pipe or pipe arch shall beformed from sheets whose base metal shall be as indicated. Inaddition, the sheets shall have been coated with a layer of fibers,applied in sheet form by pressing them into a molten metallicbonding. If a paved invert is indicated it shall be in accordance withthe procedure outlined above. The test for spelter coating above iswaived for fiber bonded pipe.

6. Slotted Drain Storm Sewers

The pipes for the slotted drain and slotted drain outfall shall be helicallycorrugated, lock seam or welded seam pipe. Materials and fabrication shall bein accordance with the above. The metal thickness shall be a minimum 16gage.The chimney assemblies shall be constructed of 3/16 inch welded plateor machine formed 14 gage galvanized steel sheets. The height of thechimney required shall be as indicated. Metal for the welded plate slotshall meet the requirements of ASTM A 36 and the completed plate slotshall be galvanized after fabrication in accordance with ASTM A 123.

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Weld areas and the heat affected zones where the slot is welded to thecorrugated pipe shall be thoroughly cleaned and painted with a goodquality asphalt base aluminum paint.

7. Mortar

Mortar shall be composed of 1 part Type I Portland Cement and 2 partsclean, sharp mortar sand suitably graded for the purpose andconforming in other respects to the provisions for fine aggregate of ItemNo. 403, "Concrete for Structures". Hydrated lime or lime putty may beadded to the mix, but in no case shall it exceed 10 percent by weight ofthe total dry mix.

SS510.3 Construction Methods

(1) General

Prior to commencing this Work, all erosion control and tree protectionmeasures required shall be in place and all utilities located and protected as setforth in "General Conditions". Clearing the site shall conform to TxDOTSpecification Item No. 100, "Preparing Right of Way". Maintenance ofenvironmental quality protection shall comply with all requirements of"General Conditions" and TxDOT Specification Item No. 160, "Furnishingand Placing Topsoil".

The Contractor shall conduct his Work such that a reasonable minimum ofdisturbance to existing utilities will result. Particular care shall be exercised toavoid the cutting or breakage of all existing utilities. If at any time theContractor damages the utilities in place through his operations, the Contractorshall immediately notify the owner of the utility to make the necessary repairs.When active wastewater sewer lines are cut in the trenching operations,temporary flumes shall be provided across the trench while open and the linesshall be restored when the backfilling has progressed to the original beddinglines of the sewer so cut.

The Contractor shall inform utility owners sufficiently in advance of theContractor's operations to enable such utility owners to reroute, providetemporary detours or to make other adjustments to utility lines in order that theContractor may proceed with his Work with a minimum of delay and expense.The Contractor shall cooperate with all utility owners concerned in effectingany utility adjustments necessary and shall not hold the City liable for anyexpense due to delay or additional Work because of conflicts arising fromexisting utilities.

The Contractor shall do all trenching in accordance with the provisions andthe directions of the E/A as to the amount of trench left unfilled at any time.All excavation and backfilling shall be accomplished as indicated and incompliance with State Statutes.

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Where excavation for a pipe line is required in an existing City street, a street cutpermit is required and control of traffic shall be as indicated in accordance withthe Texas Manual on Uniform Traffic Control Devices.

Wherever existing utility branch connections, sewers, drains, conduits, ducts,pipes or structures present obstructions to the grade and alignment of the pipe,they shall be permanently supported, removed, relocated or reconstructed by theContractor through cooperation with the owner of the utility, structure orobstruction involved. In those instances where their relocation or reconstruction isimpractical, a deviation from line and grade will be ordered by the E/A and thechange shall be made in the manner directed.

Adequate temporary support, protection and maintenance of all underground andsurface utility structures, drains, sewers and other obstructions encountered in theprogress of the Work shall be furnished by the Contractor, at his expense and asapproved by the E/A.

Where traffic must cross open trenches, the Contractor shall provide suitablebridges. For trenches less than 2 feet in width, sheet steel plates having aminimum thickness of 1/2 inch shall be used. For trenches up to 4 feet in width,sheet steel plates having a minimum thickness of 3/4 inches shall be used. In allcases, the plates shall overlay the top of the trench a minimum of 18 inches onboth sides and secured by asphalt. Adequate provisions shall be made for the flowof sewers, drains and watercourses encountered during construction and anystructures which may have been disturbed shall be satisfactorily restored uponcompletion of Work.

When rainfall or runoff is occurring or is forecast by the U.S. Weather Service,the Contractor shall not perform or attempt any excavation or other earth movingWork in or near the flood plain of any stream or watercourse or on slopes subjectto erosion or runoff, unless given specific approval by the E/A. When suchconditions delay the Work, an extension of time for working day contracts willbe allowed in accordance with "General Conditions".

(2) Water Line/New Wastewater Line Separation

Installation of new water or wastewater lines shall conform to the following:

Where feasible, water and wastewater lines shall be no closer to each other than 9 feetbetween outside diameters in all directions and shall be in separate trenches.

If the 9 foot separation cannot be achieved, any portion of a new gravity wastewaterline within 9 feet in any direction (between OD's) of a potable water line, shall be in aseparate trench and constructed of ductile iron, AWWA C-900 (SDR-18) 150 psi ratedPVC in sizes 12 inch, or AWWA C-905 (SDR-25) 165 psi rated PVC in sizes largerthan 12 inches.

If the lines are parallel, they shall not be closer than 4 feet horizontally or 2 feetvertically between OD's with the wastewater lower than the water line. If the linescross, they may be no closer than 6 inches vertically between OD's with the sewerbelow the water line and one standard 20 foot length of ductile iron, AWWA C-900

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(SDR-18) 150 psi rated PVC in sizes to 12 inch, or AWWA C-905 (SDR-25) 165 psirated PVC in sizes larger than 12 inches shall be centered at the point of crossing thewater line.

Unless wastewater manholes and the connection to the sewer can be madecompletely watertight and tested for no leakage, they must be installed so as toprovide a minimum of 9 feet of horizontal clearance from an existing orproposed water line.

(3) Utility and Storm Sewer CrossingsWhen the Contractor installs a pipe that crosses under a utility structure or stormsewer and the top of the pipe is within 18 inches of the bottom of the utilitystructure, the pipe shall be encased as specified in Item No. SS505, "ConcreteEncasement and Encasement Pipe", for a distance of at least 1 foot on either sideof the ditch line of the utility structure or the storm sewer. Unless otherwisespecified by the E/A, concrete encasement will not be required for ductile iron,AWWA C-900 (SDR-18) 150 psi rated PVC in sizes to 12 inch, or AWWA C-905 (SDR-25) 165 psi rated PVC in sizes larger than 12 inches. When theContractor installs a pipe that crosses over a utility structure or storm sewer andthe top of the utility structure or storm sewer is within 18 inches of the bottom ofthe pipe, the pipe shall be either ductile iron, AWWA C-900 (SDR-18) 150 psirated PVC in sizes to 12 inch, or AWWA C-905 (SDR-25) 165 psi rated PVC insizes larger than 12 inches, unless otherwise specified by the E/A.

Where trenches wider than 12 inches cross under existing wastewater lines, thesewer lines shall be replaced with one 20 foot joint of ductile iron, AWWA C-900 (SDR-18) 150 psi rated PVC in sizes to 12 inch, or AWWA C-905 (SDR-25) 165 psi rated PVC in sizes larger than 12 inches, centered over the trench.

(4) Trench ExcavationUnderground piped utilities shall be constructed in an open cut in accordancewith Federal regulations, applicable State Statutes conforming to TxDOTSpecification Item No. 402, "Trench Safety Systems" and with a trench widthand depth described below. When pipe is to be constructed in fill above thenatural ground, Contractor shall construct embankment to an elevation notless than one foot above the top of the pipe, after which trench is excavated.Required vertical sides shall be sheeted and braced as indicated to maintainthe sides of the required vertical excavation throughout the constructionperiod. Adequacy of the design of sheeting and bracing shall be theresponsibility of the Contractor's design professional. The Contractor shall beresponsible for installation as indicated. After the pipe has been laid and thebackfill placed and compacted to 12 inches above the top of the pipe, anysheeting, shoring and bracing required may be removed with special care toinsure that the pipe is not disturbed. As each piece of sheeting is removed, thespace left by its removal must be thoroughly filled and compacted withsuitable material and provisions made to prevent the sides of the trench fromcaving until the backfill has been completed. Any sheeting left in place willnot be paid for and shall be considered subsidiary to the pipe item bid.

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(5) Trench Width

Trenches for water and wastewater lines shall have a clear width on each sidebeyond the outside surfaces of the pipe bell or coupling of not less than 6 inches normore than 12 inches.

Trenches for Storm Sewers up to 42 inches shall have a width of 1 foot on each sidebeyond the outside surfaces of the pipe. Pipes more than 42 inches shall have atrench width not to exceed 18 inches on each side beyond the outside surfaces of thepipe.

If the trench width within the pipe zone exceeds this maximum, the entire pipe zoneshall be refilled with approved backfill material, thoroughly compacted to aminimum of 95 percent of maximum density as determined by TxDOT Test MethodTex-114-E and then re-excavated to the proper grade and dimensions. Excavationalong curves and bends shall be so oriented that the trench and pipe areapproximately centered on the centerline of the curve, using short lengths of pipeand/or bend fittings if necessary.

For all utilities to be constructed in fill above natural ground, the embankment shallfirst be constructed to an elevation not less than 1 foot above the top of the utilityafter which excavation for the utility shall be made.

(6) Trench Depth and Depth of Cover

All pipe and in-line appurtenances shall be laid to the grades indicated. The depthof cover shall be measured from the established finish grade, natural groundsurface, subgrade for staged construction, street or other permanent surface to thetop or uppermost projection of the pipe.

(a) Where not otherwise indicated, all water piping shall be laid to thefollowing minimum depths:

1. Water piping installed in undisturbed ground in easements ofundeveloped areas, which are not within existing or planned streets,roads or other traffic areas shall be laid with at least 36 inches of cover.

2. Water piping installed in existing streets, roads or other traffic areasshall be laid with at least 48 inches of cover below finish grade.

3. Unless approved by the E/A, installation of water piping in proposednew streets will not be permitted until paving and drainage plans havebeen approved and the roadway traffic areas excavated to the specifiedor standard paving subgrade, with all parkways and sidewalk areasgraded according to any applicable provisions of the drainage plans orsloped upward from the curb line to the right of way line at a minimumslope of 1/4 inch per foot. Piping and appurtenances installed in suchproposed streets shall be laid with at least 36 inches of cover below theactual subgrade.

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(b) Where not otherwise indicated, all wastewater piping shall be laid to thefollowing minimum depths:

1. Wastewater piping installed in natural ground in easements or otherundeveloped areas, which are not within existing or planned streets,roads or other traffic areas shall be laid with at least 42 inches of cover.

2. Wastewater piping installed in existing streets, roads or othertraffic areas shall be laid with at least 66 inches of cover.

3. Wastewater piping installed in such proposed streets shall be laidwith at

least 48 inches of cover below the actual subgrade.

(7) Classification of Excavation

Excavation will not be considered or paid for as a separate item of Work, soexcavated material will not be classified as to type or measured as to quantity.Full payment for all excavation required for the construction shall be includedin the various unit or lump sum Contract prices for the various items of Workinstalled, complete in place. No extra compensation, special treatment or otherconsideration will be allowed due to rock, pavement, caving, sheeting andbracing, falling or rising water, working under and in the proximity of trees orany other handicaps to excavation.

(8) Dewatering Excavation

Underground piped utilities shall not be constructed or the pipe laid in thepresence of water. All water shall be removed from the excavation prior to thepipe placing operation to insure a dry firm granular bed on which to place theunderground piped utilities and shall be maintained in such unwateredcondition until all concrete and mortar is set. Removal of water may beaccomplished by bailing, pumping or by a well-point installation as conditionswarrant.

In the event that the excavation cannot be dewatered to the point where thepipe bedding is free of mud, a seal shall be used in the bottom of theexcavation. Such seal shall consist of Class B concrete, conforming to TxDOTSpecification Item No. 421, "Portland Cement Concrete", with a minimumdepth of 3 inches.

(9) Trench Conditions

Before attempting to lay pipe, all water, slush, debris, loose material, etc.,encountered in the trench must be pumped or bailed out and the trench must bekept clean and dry while the pipe is laid and backfilled. Where needed, sumppits shall be dug adjoining the trench and pumped as necessary to keep theexcavation dewatered.

Backfilling shall closely follow pipe laying so that no pipe is left exposed andunattended after initial assembly. All open ends, outlets or other openings inthe pipe shall be protected from damage and shall be properly plugged and

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blocked watertight to prevent the entrance of trench water, dirt, etc. Theinterior of the pipeline shall at all times be kept clean, dry and unobstructed.

Where the soil encountered at established footing grade is a quicksand,saturated or unstable material, the following procedure shall be used unlessother methods are indicated:

All unstable soils shall be removed to a depth of a minimum 2 feet belowbottom of piped utility or as required to stabilize the trench foundation. Suchexcavation shall be carried out for the entire trench width.

All unstable soil so removed shall be replaced with a concrete seal, foundationrock or coarse aggregate materials placed across the entire trench width inuniform layers not to exceed 6 inches, loose measure and compacted bymechanical tamping or other means which shall provide a stable foundation forthe utility.

Forms, sheathing and bracing, pumping, additional excavation and backfillrequired in unstable trench conditions shall be subsidiary to pipe bid.

(10) BlastingAll blasting shall conform to the provisions of the "General Conditions" and/or"Public Safety and Convenience".

(11) Removing Old StructuresWhen out of service masonry structures or foundations are encountered in theexcavation, such obstructions shall be removed for the full width of the trenchand to a depth of 1 foot below the bottom of the trench. When abandoned inletsor manholes are encountered and no plan provision is made for adjustment orconnection to the new sewers, such manholes and inlets within the constructionlimits shall be removed completely to a depth 1 foot below the bottom of thetrench. In each instance, the bottom of the trench shall be restored to grade bybackfilling and compacting by the methods provided above. Where the trenchcuts through storm or wastewater sewers which are known to be abandoned,these sewers shall be cut flush with the sides of the trench and blocked with aconcrete plug in a manner satisfactory to the E/A. When old structures areencountered, which are not visible from the existing surface and are still inservice, they shall be protected and adjusted as required to the finished grade.

(12) Lines and GradesGrades, lines and levels shall conform to the General Conditions and/or"Grades, Lines and Levels". Any damage to the above by the Contractor shallbe re-established at the Contractor's expense. The Contractor shall furnishcopies of all field notes and "cut sheets" to TxDOT and/or the City of Austin.

The location of the lines and grades indicated may be changed only by directionof the E/A and it is understood that the Contractor will be paid on the basis ofhis unit Contract prices bid for such Work actually performed and shall make

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no claim for damages or loss of anticipated profits due to the change of locationor grade.

The Contractor shall furnish, at his expense, all necessary batter boards orelectronic devices for controlling the Work. Batter boards shall be of adequatesize material and shall be supported substantially. The boards and all locationstakes must be protected from possible damage or change of location. TheContractor shall furnish good, sound twilled lines for use in achieving lines andgrades and the necessary plummets and graduated poles.

The Contractor shall submit to the E/A at least 6 copies of any layout Drawingsfrom the pipe manufacturer for review and approval. The Contractor shallsubmit the layout Drawings at least 30 days in advance of any actualconstruction of the project. The E/A will forward all comments of the review tothe Contractor for revision. Revisions shall be made and forwarded to the E/Afor his acceptance. Prior to commencement of the Project, reviewed layoutDrawings will be sent to the Contractor marked for construction.

Should the Contractor's procedures not produce a finished pipe placed tograde and alignment, the pipe shall be removed and relayed and theContractors procedures modified to the satisfaction of the E/A. Noadditional compensation shall be paid for the removal and relaying ofpipe required above.

(13) Surplus Excavated MaterialsExcess material or material which cannot be made suitable for use inembankments will be declared surplus by the E/A and shall become theproperty of the Contractor to dispose of off site at a permitted fill site, withoutliability to the City or any individual. Such surplus material shall be removedfrom the Work site promptly following the completion of the portion of theutility involved.

(14) Pipe Bedding EnvelopePipe shall be installed in a continuous bedding envelope of the type shown onthe drawings or as described herein. The envelope shall extend the full trenchwidth, to a depth of 6 inches below the pipe and shall rise at least to thespringline of stormwater pipe and to 12 inches above water and wastewaterpipe.

(a) Standard Bedding Materials

PIPE BEDDING STONE

USE / PIPEMATERIAL

CementStabilizedBackfill

Naturalor Mf'dSand

PeaGravel

UncrushedGravel

CrushedGravel

CrushedStone

StoneScreenings

WATERWelded Steel X X

Service Tubing3/4" to 2-1/2" X X X

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WATER and WASTEWATERUp to 15 Inch ID X X X X X XLarger Than 15

Inch ID X X X XSTORMWATER

Concrete X X X X X XMetal X X X X

(b) General requirements and limitations governing bedding selection.

(1) Crushed gravel or crushed stone shall not be used with polyethylenetubing or polyethylene film wrap.(2) Uncrushed gravel may be used with polyethylene film wrap intrenches up to 6 feet deep and in deeper trenches where ample trenchwidth, a tremmie, or conditions will allow controlled placement of thegravel without damaging the polyethylene wrap.(3) Bedding shall be placed in lifts not exceeding 8 inches loosethickness and compacted thoroughly to provide uniform support for thepipe barrel and to fill all voids around the pipe.(4) Pea Gravel or bedding stone shall be used in blasted trenches.

(c) Requirements to prevent particle migration.

Bedding material shall be compatible with the materials in the trenchbottom, walls and backfill so that particle migration from, into or throughthe bedding is minimized. The E/A may require one or more of thefollowing measures to minimize particle migration: use of impervious cut-off collars; selected bedding materials, such as pea gravel or bedding stonemixed with sand; filter fabric envelopment of the bedding; cementstabilized backfill; or other approved materials or methods. Measures tominimize particle migration will be shown on the Drawings or designatedby the E/A, and, unless provisions for payment are provided in the contractdocuments, the cost of these measures shall be agreed by change order.The following limitations shall apply.

(1) Sand, alone, shall not be used in watercourses, in trenches wheregroundwater is present, or in trenches with grades greater than 5percent.

(2) Pea gravel or bedding stone, alone, shall not be used in the street right-of-way within 5 feet of subgrade elevation in trenches that are 3 feetor wider.

(3) Pea gravel or bedding stone, alone, shall not be used where the trenchbottom, sides, or backfill is composed of non-cementitious, silty orsandy soils having plasticity indices less than 20, as determined by theE/A.

(15) Laying Pipe

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No pipe shall be installed in the trench until excavation has been completed,the bottom of the trench graded and the trench completed as indicated.

Laying of corrugated metal pipes on the prepared foundation shall be startedat the outlet end with the separate sections firmly joined together, withoutside laps of circumferential joints pointing upstream and with longitudinallaps on the sides. Any metal in joints, which is not protected by galvanizing,shall be coated with suitable asphaltum paint. Proper facilities shall beprovided for hoisting and lowering the sections of pipe into the trenchwithout damaging the pipe or disturbing the prepared foundation and thesides of the trench. Any pipe which is not in alignment or which shows anyundue settlement after laying or damage, shall be taken up and relaid withoutextra compensation.

Multiple installations of corrugated pipe or arches shall be laid with thecenterlines of individual barrels parallel. When not otherwise indicated, cleardistances of 2 feet between outer surfaces of adjacent pipes shall bemaintained.

No debris shall remain in the drainways or drainage structures.

All recommendations of the manufacturer shall be carefully observed duringhandling and installation of each material. Unless otherwise indicated, allmaterials shall be delivered to the project by the manufacturer or agent andunloaded as directed by the Contractor. Each piece shall be placed facing theproper direction near to where it will be installed.

The interior of all pipe, fittings and other accessories shall be kept free fromdirt and foreign matter at all times and stored in a manner that will protectthem from damage. Stockpiled materials shall be stacked so as to minimizeentrance of foreign matter.

The interior of all pipeline components shall be clean, dry and unobstructedwhen installed.

Piping materials shall not be skidded or rolled against other pipe, etc. andunder no circumstances shall pipe, fittings or other accessories be dropped orjolted.

During handling and placement, materials shall be carefully observed andinspected and any damaged, defective or unsound materials shall be marked,rejected and removed from the job site. Minor damage shall be marked andrepaired in a manner satisfactory to the E/A. Joints, which have been placed,but not joined, backfilled, etc., shall be protected in a manner satisfactory tothe E/A.

(16) Assembling of PipeAngular spacing of all joints shall meet the manufacturer's recommendationsfor the pipe and accessories being used. Side outlets shall be rotated so thatthe operating stems of valves shall be vertical when the valves are installed.

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Pressure pipe shall be laid with bell ends facing the direction of pipeinstallation. Pipe end bells shall be placed upgrade for all wastewater lines.

Orientation marks, when applicable, shall be in their proper position beforepipe is seated.

Before joining any pipe, all foreign matter, lumps, blisters, excess coal tarcoating, oil or grease shall be removed from the ends of each pipe and thepipe ends shall then be wire brushed and wiped clean and dry. Pipe ends shallbe kept clean until joints are made.

Every precaution shall be taken to prevent foreign material from entering thepipe during installation. No debris, tools, clothing or other materials shall beplaced in the pipe.

(17) Joints(a) Mortar (Storm Drain joints only)

Pipe ends shall be clean, free of asphalt or other contaminants, which willinhibit the bond of the mortar to the pipe. The pipe ends shall be moistenedimmediately prior to placing the mortar in the joint.

(b) Cold Applied Preformed Plastic Gaskets (Storm Drain joints only)

The pipe ends shall be clean and the joint material applied to the dry pipe.In cold weather, the joint material shall be heated to facilitate the seal ofthe joint.

(c) O-Ring and Push-on Joints

Just before making a joint the ends of the pipe shall be clean, dry, free ofany foreign matter, lump blisters, excessive coal tar coating and grease oroil and shall be wire brushed. The gasket and the inside surface of the bellshall be lubricated with a light film of soft vegetable soap compound (FlaxSoap) to facilitate telescoping the joints. The rubber gasket if not factoryinstalled shall be stretched uniformly as it is placed in the spigot groove toinsure a uniform volume of rubber around the circumference of the groove.The spigot shall be centered in the bell, the pipe pushed home uniformlyand brought into true alignment. Bedding material shall be placed andtamped against pipe to secure the joint.. Care should be taken to preventdirt or foreign matter from entering the joint space.

(d) Bolted Joints

All flanged, mechanical or other bolted joints shall be joined with nuts andbolts and be coated as indicated above in Iron Pipe.

(18) Pressure Pipe Laying

(a) Grout for Concrete Steel Cylinder Pipe (CSC) and Welded Steel Pipe

Aggregate, cement, etc., shall be as indicated in "Mortar" herein.

Grout shall be poured into the recess between the bell and spigot on theoutside of the pipe and contained by a joint wrapper ("diaper") recommended

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by the pipe manufacturer. The wrapper shall have a minimum width of 7inches for 30 inch and smaller and 9 inches for larger pipe, secured to the pipeby "Band Iron" steel straps. The grout shall be poured in one continuousoperation in such manner that after shrinkage and curing the joint recess shallbe completely filled.

Mortar for the inside recess shall be of the consistency of plaster. The insiderecess between the bell and spigot shall be filled with mortar after the pipejoint on either side of the recess has been backfilled and well tamped with noless than one pipe joint installed ahead of the pipe forming the recess. Themortar shall completely fill the recess and shall be trowelled and packed intoplace and finished off smooth with the inside of the pipe.

The Contractor shall inspect the joint after the mortar has set and make repairsof any pockets, cracks or other defects caused by shrinkage to the satisfactionof the E/A. The inside surface shall be cleared of any mortar droppings,cement, water, slurry, etc., before they have become set and shall be cleared ofany other foreign matter. The inside surface of the pipe shall be left clean andsmooth.

Pipe shall be handled at all times with wide non abrasive slings, belts or otherequipment designed to prevent damage to the coating and all such equipmentshall be kept in such repair that its continued use is not injurious to thecoating. The use of tongs, bare pinch-bars, chain slings, rope slings withoutcanvas covers, canvas or composition belt slings with protruding rivets, pipehooks without proper padding or any other handling equipment which the E/Adeems to be injurious to the coating shall not be permitted. The spacing of pipesupports required to handle the pipe shall be adequate to prevent cracking ordamage to the cement mortar lining.

(19) Placing Pipe in Tunnels

Piping installed as a carrier pipe in a tunnel, encasement pipe, etc., shall haveuniform alignment, grade, bearing and conform to the reviewed ShopDrawings. All necessary casing spacers, bedding material, grout cradle orpaving, bracing, blocking, etc., as stipulated by the Contract or as may berequired to provide and maintain the required pipe alignment and grade, shallbe provided by the Contractor at no cost except as provided by the Bid Items.This shall include casing spacers acceptable to the Owner attached to thecarrier pipe in accordance with the manufacturer's recommendations. Theinsertion pushing forces shall not exceed the pipe manufacturer'srecommendation. Such carrier piping shall have flexible bolted or gasketedpush-on joints or Concrete Steel Cylinder pipe installed as follows:

(a) 21 Inch Pipe and Smaller

Prior to placing the pipe in the tunnel, the inside joint recess at the bellshall be buttered with cement mortar.

After the joint is engaged, the excess mortar shall be smoothed by pullinga tight fitting swab through the joint. Cement mortar protection shall then

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be placed in the normal manner to the exterior of the joint and allowed toharden sufficiently to avoid dislodgment during installation. If time is ofthe essence, a quick setting compound may be used.

(b) 24 Inch Pipe and Larger

Each length of pipe shall be pushed into the tunnel as single units. Aflexible mastic sealer shall be applied to the exterior of the joint prior tojoint engagement. The surfaces receiving the mastic sealer shall be cleanedand primed in accordance with the manufacturer's recommendation.Sufficient quantities of the mastic sealer shall be applied to assurecomplete protection of all steel in the joint area. The interior of the jointshall be filled with cement mortar in the normal manner after the pipe is inits final position within the tunnel.

(20) Temporary Pipe Plugs, Caps, Bulkheads and Trench Caps

Temporary plugs, caps or plywood bulkheads shall be installed to close allopenings of the pipe and fittings when pipeline construction is not in progress.

All temporary end plugs or caps shall be secured to the pipe as provided underCity of Austin Standard Specification Item No. 507, "Bulkheads".

Trench caps shall be reinforced Class D concrete as indicated.

(21) Corrosion Control

(a) Protective Covering

Unless otherwise indicated, all flanges, nuts, bolts, threaded outlets and allother iron or steel components buried and in contact with earth or backfillshall be wrapped with 8-mil (minimum) polyethylene film meetingANSI/AWWA C-105 to provide a continuous wrap.

(22) Pipe Anchorage, Support and Protection

Pressure pipeline tees, plugs, caps and bends exceeding 22 1/2 degrees; otherbends as directed shall be securely anchored by suitable concrete thrustblocking or by approved metal harness. Unless otherwise indicated, on 24 inchor larger piping, all bends greater than 11 1/4 degrees shall be anchored asdescribed herein.

Storm sewers on steep grades shall be lugged as indicated.

(a) Concrete Thrust Blocking

Concrete for use as reaction or thrust blocking shall be Class Bconforming to TxDOT Specification Item No. 421, "Portland CementConcrete".

Concrete blocking shall be placed between solid ground and the fitting tobe anchored. The area of bearing on the pipe and on the ground shall be asindicated or directed by the E/A. The blocking shall, unless otherwise

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indicated, be so placed that the pipe, fittings and joints will be accessiblefor repair.

The trench shall be excavated at least 6 inches outside the outermostprojections of the pipe or appurtenance and the trench walls shaped orundercut according to the detail Drawings or as required to provideadequate space and bearing area for the concrete.

The pipe and fittings shall be adequately weighted and laterally braced toprevent floating, shifting or straining of the pipeline while the concrete isbeing placed and taking initial set. The Contractor shall be solelyresponsible for the sufficiency of such restraints.

(b) Metal Thrust Restraint

Fabricated thrust restraint systems such as those described below may beapproved for use instead of concrete blocking. To obtain approval, theproject Drawings must include sufficient drawings, notes, schedules, etc.,to assure that the proposed restraints as installed will be adequate toprevent undesirable movement of the piping components. Such restraintsystems may only be used where and as specifically detailed andscheduled on approved Project Drawings.

1. Thrust Harness

A metal thrust harness of tie rods, pipe clamps or lugs, turnbuckles,etc., may be approved. All carbon steel components of such systems,including nuts and washers, shall be hot-dip galvanized; all othermembers shall be cast ductile iron. After installation, the entireassembly shall be wrapped with 8 mil polyethylene film, overlappedand taped in place with duct tape to form a continuous protectivewrap.

2. Restrained Joints

Piping or fitting systems utilizing integral mechanically restrainedjoints may be approved. All components of such systems shall bestandard manufactured products fabricated from cast ductile iron, hot-dip galvanized steel, brass or other corrosion resistant materials andthe entire assembly shall be protected with a continuous film wrap asdescribed for 1. above.

Location, configuration and description of such products shall bespecifically detailed on the Drawings. (Add-on attachments such asretainer glands, all-thread rods, etc., are not acceptable.)

(c) Concrete Encasement, Cradles, Caps and Seals

When trench foundation is excessively wet or unstable or installation ofwater or wastewater pipe will result in less than 30 inches of cover,

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Contractor shall notify E/A. E/A may require Contractor to install aconcrete seal, cradle, cap, encasement or other appropriate action.

All concrete cap, etc., shall be continuous and begin and end within 6inches of pipe joints. Concrete cap, cradle and encasement shall conform toCity of Austin Standard No. 510-1. The pipe shall be well secured toprevent shifting or flotation while the concrete is being placed.

(d) Anchorage Bulkheads

Concrete bulkheads keyed into the undisturbed earth shall be placed asindicated to support and anchor the pipe and/or backfill against end thrust,slippage on slopes, etc. Concrete material and placement shall be Class A,TxDOT Specification Item No. 421, "Portland Cement Concrete".

(e) Trench Caps, Concrete Rip-Rap and Shaped Retards

Where called for by the Contract or as directed by the E/A, concrete trenchcaps, concrete rip-rap and/or shaped retards shall be placed as detailed bythe Drawings as protection against erosion. Concrete material andplacement shall be Class B, TxDOT Specification Item No. 421, "PortlandCement Concrete".

(23) Wastewater Connections

(a) Connections to Mains 12 Inches and Smaller

All branch connections of new main lines shall be made by use ofmanholes.

Service stubs shall be installed as indicated. Minimum grade shall be 1percent downward to main and minimum cover shall be 4 1/2 feet at thecurb. Standard plugs shall be installed in the dead end before backfilling.

Where a service connection to a main 12 inches or smaller is indicated, awye, tee or double wye shall be installed.

Where a service connection to a main 15 inches or larger is indicated, afield tap may be made with the pipes installed crown to crown. The tapshould be made conforming to the pipe manufacturer's recommendationswith the E/A’s approval.

Where not otherwise indicated, (wastewater) service connections shall beinstalled so that the outlet is at an angle of not more than 45 degrees abovehorizontal at the main line.

(b) Connections to the Existing System

Unless otherwise specified by the E/A, all connections made to existingmains shall be made at manholes with the crown of the inlet pipe installedat the same elevation as the crown of the existing pipe. Service stubsinstalled on the existing system shall be installed by use of tapping saddlesunless otherwise approved by the E/A. Extreme care shall be exercised to

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prevent material from depositing in the existing pipe as the taps are beingmade.

When connections to existing mains are made, a temporary plug approvedby the E/A must be installed downstream in the manhole to prevent waterand debris from entering the existing system before Final Completion.These plugs shall be removed after the castings are adjusted to finish gradeor prior to Final Completion.

(24) Water System ConnectionsThe Contractor shall, at his expense, make all necessary connections of newpiping or accessories to the existing water system. To minimize anyinconvenience from outages, the Contractor shall schedule all suchconnections in advance and such schedule must be approved by the E/A beforebeginning any Work.

(a) Shutoffs

The City will make all shutoffs on existing water mains. The Contractorshall be required to notify the E/A’s field representative on the job at least72 hours prior to the desired time for any shutoff. The E/A’s fieldrepresentative will notify any affected utility customers at least 24 hoursprior to the shutoff. The Water Utility will make the shutoff after ensuringthat all appropriate measures have been taken to protect the water system,customers and employees.

The City will operate all valves to fill existing mains. Where a newlyconstructed main has not been placed in service and has only oneconnection to the public water supply, the Contractor may operate onevalve to fill the main after approval has been obtained from the WaterUtility. The operation of the valve is to be conducted under the immediatesupervision of the E/A’s field representative.

Water for the Work shall be metered and furnished by the Contractor inaccordance with Section 01500.

(b) Wet Connections to Existing Water System

The Contractor shall make all wet connections called for by the Contractor required to complete the Work. Two connections to an existing lineperformed during the same shut-out, at the same time and at a distanceless than 50 linear feet apart, will be considered one wet connection. Twoconnections to an existing line performed during the same shut-out, at thesame time and at a distance equal to, or greater than 50 linear feet will beconsidered two wet connections. A wet connection shall include drainingand cutting into existing piping and connecting a new pipeline or otherextension into the existing pressure piping, forming an addition to thewater transmission and distribution network.

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The Contract price for wet connections shall be full payment for allnecessary shutoffs, excavation, removing plugs and fittings, pumpingwater to drain the lines, cutting in new fittings, blocking and anchoringpiping, bedding and backfilling, placing the lines and service and all sitecleanup.

No water containing detectable amounts of chlorine may be drained,released or discharged until specific planning and appropriatepreparations to handle, dilute and dispose of such chlorinated water areapproved in advance by the City and the disposal operations will bewitnessed by an authorized representative from the City.

(c) Pressure Taps to Existing Water System

The Contractor shall make all pressure taps called for by the ContractDocuments or required to complete the Work. A pressure tap shall consistof connecting new piping to the existing water system by drilling into theexisting pipe while it is carrying water under normal pressure withouttaking the existing piping out of service.

Unless otherwise provided by the Contract, the Contractor shall, at hisexpense, perform all necessary excavation, furnish and install the tappingsleeve, valve and accessories, provide the tapping machine, drill the tapand shall block, anchor and backfill the piping, valve and all accessories,place the new piping in service and perform all site cleanup. When theCity makes the tap, City forces are not obligated or expected to performany Work except to provide tapping machine and drill the actual hole. IfCity crews are to make the tap, fiscal arrangements must be made inadvance at the Taps Office, Waller Creek Center, 625 East 10th Street.

If a private Contractor makes the tap, a W-WW Inspector must bepresent. "Size on size" taps will not be permitted, unless made by use ofan approved full circle gasket tapping sleeve. Concrete blocking shall beplaced behind and under all tap sleeves 24 hours prior to making the wettap.

(d) Service Connections

Service connection taps into PVC or AC pipe or into CI or DI pipe 12inches or smaller shall be made using either a service clamp or saddle or atapping sleeve as recommended by the pipe manufacturer and asapproved by the E/A. Direct tapping of these pipes will not be permitted.

All water service connections shall be installed so that the outlet is at anangle of not more than 45 degrees above horizontal at the main line.

Precautions should be taken to ensure that the tapping saddle or sleeve isplaced on the pipe straight to prevent any binding or deformation of thePVC pipe. The mounting chain or U-bolt strap must be tight.

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Tapping shall be performed with a sharp shell type cutter so designed thatit will smoothly penetrate heavy walled PVC DR14 and 200 psi AC andwill retain and extract the coupon from the pipe.

(25) Backfilling(a) General

Special emphasis is placed upon the need to obtain uniform densitythroughout the backfill material. The maximum lift of backfill shall bedetermined by the compaction equipment selected and in no case shall itexceed 18 inches, loose measurement.

No heavy equipment, which might damage pipe, will be allowed over thepipe until sufficient cover has been placed and compacted. All internalpipe bracing installed or recommended by the manufacturer shall be keptin place until the pipe bedding and trench backfill have been completedover the braced pipe section. Testing of the completed backfill in streetsand under and around structures shall meet the specified densityrequirements. Initial testing shall not be at Contractor's expense and shallconform to the "General Conditions."

(b) General Corrugated Metal PipeAfter the corrugated metal pipe structure has been completely assembled onthe proper line and grade and headwalls constructed where indicated;selected material free from rocks over 8 inches in size from excavation orborrow, as approved by the E/A, shall be placed along both sides of thecompleted structures equally, in uniform layers not exceeding 6 inches indepth (loose measurement), sprinkled if required and thoroughly compactedbetween adjacent structures and between the structures and the sides of thetrench.

Backfill material shall be compacted to the same density requirements asindicated for the adjoining sections of embankment in accordance with thegoverning specifications thereof. Above the 3/4 point of the structure, the fillshall be placed uniformly on each side of the pipe in layers not to exceed 12inches, loose measure.

Prior to adding each new layer of loose backfill material, until a minimum of12 inches of cover is obtained over the crown of the pipe, an inspection willbe made of the inside periphery of the corrugated metal structure todetermine if any floating, local or unequal deformation has occurred as aresult of improper construction methods.

(c) Backfill Materials

The E/A may approve any of the following well graded materials:1. Select trench material2. Sand3. Crushed rock cuttings4. Rock cuttings

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5. Foundation Rock6. Blasted material with fines and rock7. Cement stabilized material8. Borrow

Within the 100 year flood plain, sand will not be permitted for backfilling.The E/A will approve the topsoil for areas to be seeded or sodded.

(d) Backfill in Street Right of Way

Placement of backfill under existing or future pavement structures and within 2 feetof any structures shall be compacted to the required density using any method, typeand size of equipment, which will give the required compaction without damagingthe pipe or bedding. Placement of backfill greater than 2 feet beyond structures inRight of Way shall be conform to (g) below. The depth of layers, prior tocompaction, shall depend upon the type of sprinkling and compacting equipmentused and the test results thereby obtained. Prior to and in conjunction with thecompaction operation, each layer shall be brought to the moisture content necessaryto obtain the required density and shall be kept level to insure uniform compactionover the entire layer. Testing for density shall be in accordance with Test MethodTex-114-E and Test Method Tex-115-E.

Each layer of backfill must provide the density as required herein. Swellingsoils (soils with plasticity index of 20 or more) shall be sprinkled as requiredto provide not less than optimum moisture nor more than 2 percent overoptimum moisture content and compacted to the extent necessary to providenot less than 95 percent nor more than 102 percent of the density asdetermined in accordance with Test Method Tex-114-E. Nonswelling soils(soils with plasticity index less than 20) shall be sprinkled as required andcompacted to the extent necessary to provide not less than 95 percent of thedensity as determined in accordance with Test Method Tex-114-E.

After each layer of backfill is complete, tests may be made by the E/A. If thematerial fails to meet the density indicated, the course shall be reworked asnecessary to obtain the indicated compaction and the compaction methodshall be altered on subsequent Work to obtain indicated density.

At any time, the E/A may order proof rolling to test the uniformity ofcompaction of the backfill layers. All irregularities, depressions, weak orsoft spots that develop shall be corrected immediately by the Contractor.

Should the backfill, due to any reason, lose the required stability, density orfinish before the pavement structure is placed, it shall be recompacted andrefinished at the sole expense of the Contractor. Excessive loss of moisturein the subgrade shall be prevented by sprinkling, sealing or covering with asubsequent backfill layer or granular material. Excessive loss of moistureshall be construed to exist when the subgrade soil moisture content is morethan 4 percent below the optimum of compaction ratio density. Backfill shallbe placed from the top of the bedding material to the existing grade, basecourse, subgrade or as indicated. The remainder of the street backfill shall be

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Flexible Base, Concrete or Hot Mix Asphalt Concrete as indicated or toreplaced in kind to the surface removed to construct the pipe.

(e) Backfill in County Street or State Highway Right of Way

All Work within the right of way shall meet the requirements of (d) above,as a minimum and shall meet the requirements of the permit issued by theCounty when their requirements are more stringent. Prior to the start ofconstruction, the Contractor shall be responsible for contacting theappropriate TxDOT office or County Commissioner's Precinct Office andfor coordinating his activities with the operating procedures in effect forutility cut permits and pavement repair under their jurisdiction. Approval forall completed Work in the State or County right of way shall be obtainedfrom the appropriate Official prior to final payment by the Owner.

(f) Backfill in Railroad Right of Way

All Work within the railroad right of way shall meet the requirements of (d)above, as a minimum and shall meet the requirements of the permit issuedby the Railroad Owner when their requirements are more stringent.Approval for all completed Work in the railroad right of way shall beobtained from the Railroad prior to Final Completion.

(g) Backfill in Easements

Where not otherwise indicated, Contractor may select whatever methods andprocedures may be necessary to restore entire Work area to a safe, useful andgeologically stable condition with a minimum density of 85 percent or adensity superior to that prior to construction.

In and near flood plain of all streams and watercourses, under or adjacent toutilities, structures, etc., all backfill shall be compacted to a density of not less than95 percent conforming to TxDOT Test Method Tex-114-E, unless otherwisedirected by E/A.

All soil areas disturbed by construction shall be covered with top soil and seededconforming to TxDOT Specification Item No. 164, "Seeding for Erosion Control".All turf, drainways and drainage structures shall be constructed or replaced to theiroriginal condition or better. No debris shall remain in the drainways or drainagestructures.

(26) Quality Testing for Installed Pipe(a) Wastewater Pipe Acceptance Testing

After construction is complete, E/A will determine whether the pipeline is tobe tested for infiltration, exfiltration or by the low pressure air test method. Inaddition, plastic pipe 18 inches and larger in diameter shall be deflectiontested.

Wastewater pipe installed in the City of Austin and its ETJ areas shall betested for exfiltration or infiltration as described below in "Exfiltration Test"and "Infiltration Test" or by acceptable low pressure air test, as described

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below. At the conclusion of either test series, the Work shall be further testedfor pipeline settlement and also for deflection as described below. TheContractor shall be solely responsible for making proper repairs to thoseelements, which do not pass these test requirements.

(b) Exfiltration Test

Water for the Work shall be metered and furnished by the Contractor inaccordance with Section 01500.

The pipeline shall be completely filled with water for its complete length or bysections as determined by the E/A. If tested for its complete length, themaximum head at any point shall not exceed 25 feet unless otherwiseindicated. If tested in sections, the manholes in the test section shall becompletely filled with water. After the pipeline has been filled and allowed tostand for 24 hours, the amount of exfiltration shall be calculated. Any amountin excess of 200 gallons per inch of inside pipe diameter per mile per day shallbe cause for rejection.

For portions of lines located within the Edwards Aquifer Recharge Zone orwithin any recharge area or recharge feature within the Edwards AquiferTransition Zone, the minimum head during testing shall not be less than 2 feetand the leakage rate shall not exceed 50 gallons per inch of inside pipediameter per mile per day. This rate shall apply for the entire portion of theline extending up to the first manhole located outside the recharge zone,recharge area, or recharge features indicated on Drawings and shall also beapplicable for any recharge areas or recharge features which may be identifiedduring construction. For construction within the 25 year flood plain, theexfiltration rate shall not exceed 10 gallons per inch diameter per mile of pipeper 24 hours at the same minimum test head.

(c) Infiltration Test

When the pipe placed in easements is completed, the upper portion of thetrench backfill shall be removed to a depth of not less than 18 inches belowthe finished surface and width equal to the original trench width. The trenchshall then be flooded with water until it is completely saturated and waterstands in the ditch a minimum of 12 inches deep. In cases of steep terrain,earthen dikes shall be used to assure that water will stand over the trench.After it is apparent that the trench is completely saturated, the main shall thenbe inspected with closed-circuit television for infiltration. Any section of themain or any service stub that indicates infiltration above the maximumquantity specified shall be cause for rejection.

This procedure shall not be used for pipes installed in areas where thePlasticity Index (P.I.) of the surrounding material is 20 or higher or where thebackfill material has a P.I. of 20 or more.

For portions of lines located within the Edwards Aquifer Recharge Zone orwithin any recharge area or recharge feature within the Edwards AquiferTransition Zone, the total infiltration as determined by water test, must be at a

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rate not greater than 50 gallons per inch of pipe diameter per mile of pipe per24 hours at a minimum test head of two feet. This rate shall apply for theentire portion of the line extending up to the first manhole located outside therecharge zone, recharge area, or recharge features indicated on Drawings andshall also be applicable for any recharge areas or recharge features which maybe identified during construction. For construction within the 25 year floodplain, the infiltration rate shall not exceed 10 gallons per inch diameter permile of pipe per 24 hours at the same minimum test head.

If the quantity of infiltration exceeds the maximum quantity specified,remedial action must be undertaken in order to reduce the infiltration to anamount within the limits specified.

(d) Pipeline Settlement Test

During the infiltration test or after the exfiltration test, the pipe will be TVinspected for possible settlement. When air testing has been used, water shallbe flowed into the pipe to permit meaningful observations. Any pipesettlement which causes excessive ponding of water in the pipe shall be causefor rejection. Excessive ponding shall be defined as a golf ball (1-5/8” dia.)submerged at any point along the line.

(e) Low Pressure Air Test of Plastic Gravity Flow Wastewater Lines

(1) General

Wastewater lines, at the discretion of the E/A, shall be air tested betweenmanholes. Backfilling to grade shall be completed before the test and alllaterals and stubs shall be capped or plugged by the Contractor so as notto allow air losses, which could cause an erroneous, test result. Manholesshall be plugged so they are isolated from the pipe and cannot beincluded in the test.

All plugs used to close the sewer for the air test shall be capable ofresisting the internal pressures and must be securely braced. Place all airtesting equipment above ground and allow no one to enter a manhole ortrench where a plugged sewer is under pressure. Release all pressurebefore the plugs are removed. The testing equipment used must include apressure relief device designed to relieve pressure in the sewer under testat 10 psi or less and must allow continuous monitoring of the testpressures in order to avoid excessive pressure. Use care to avoid theflooding of the air inlet by infiltrated ground water. (Inject the air at theupper plug if possible.) Use only qualified personnel to conduct the test.

(2) Ground Water

Since the presence of ground water will affect the test results, testholes shall be dug to the pipe zone at intervals of not more than 100feet and the average height of ground water above the pipe (if any)shall be determined before starting the test.

(3) Test Procedure

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The E/A may, at any time, require a calibration check of theinstrumentation used. Use a pressure gauge having minimumdivisions of 0.10 psi and an accuracy of 0.0625 psi. (One ounce persquare inch.) All air used shall pass through a single control panel.Clean the sewer to be tested and remove all debris where indicated.Wet the sewer prior to testing. The average back pressure of anygroundwater shall be determined (0.433 psi) for each foot of averagewater depth (if any) above the sewer.

Add air slowly to the section of sewer being tested until the internalair pressure is raised to 4.0 psig greater than the average back pressureof any ground water that may submerge the pipe. After the internaltest pressure is reached, allow at least 2 minutes for the airtemperature to stabilize, adding only the amount of air required tomaintain pressure. After the temperature stabilization period,disconnect the air supply. Determine and record the time in secondsthat is required for the internal air pressure to drop from 3.5 psig to2.5 psig greater than the average back pressure of any ground waterthat may submerge the pipe. Compare the time recorded with thespecification time for the size and length of pipe as given in thefollowing table:

Table For Low Pressure Air Testing of Plastic Pipe:

Minimum Specified Time RequiredFor 1.0 psig Pressure DropFor Size and Length of Pipe Indicated

Diameter ofPipe, (in.) Specification Time (min-:sec) for length shown

100 ft 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 450 ft4 3:46 3:46 3:46 3:46 3:46 3:46 3:46 3:466 5:40 5:40 5:40 5:40 5:40 5:40 5:42 6:248 7:34 7:34 7:34 7:34 7:36 8:52 10:08 11:2410 9:26 9:26 9:26 9:53 11:52 13:51 15:49 17:4812 11:20 11:20 11:24 14:15 17:05 19:56 22:47 25:3815 14:10 14:10 17:48 22:15 26:42 31:09 35:36 40:0418 17:00 19:13 25:38 32:03 38:27 44:52 51:16 57:4121 19:50 26:10 34:54 43:37 52:21 61:00 69:48 78:3124 22:47 34:11 45:34 56:58 68:22 79:46 91:10 102:3327 28:51 43:16 57:41 72:07 86:32 100:57 115:22 129:4830 35:37 53:25 71:13 89:02 106:50 124:38 142:26 160:1533 43:05 64:38 86:10 107:43 129:16 150:43 172:21 193:5336 51:17 76:55 102:34 128:12 153:50 179:29 205:07 230:46

NOTES: 1. Specification times are as given in UNI-B-6RECOMMENDED PRACTICE FOR LOW-PRESSURE

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TESTING OF INSTALLED PIPE -- by Uni-Bell PVC PipeAssociation, 2655 Villa Creek Dr., Ste. 155, Dallas Texas75234.

2. Pipe Sizes acceptable by City of Austin are as given in theWater and Wastewater Utility’s Standard Products List (SPL's)WW-227 and WW-227A.

Any drop in pressure, from 3.5 psig to 2.5 psig (adjusted forgroundwater level), in a time less than that required by the above tableshall be cause for rejection. When the line tested includes more than onesize pipe, the minimum time shall be that given for the largest size pipeincluded.

Test procedure for wastewater pipe located in the Edwards AquiferRecharge Zone or identified recharge areas or recharge features withinthe Edwards Aquifer Transition Zone:

Low-pressure air tests must conform to the procedure described inASTM C-924 or other equivalent procedures. For safety reasons, airtesting of pipe sections will be limited to line sizes of 36 inches insidediameter or less. Lines that are 36 inches or larger inside diameter maybe air tested at each joint. The minimum time allowable for the pressureto drop from 3.5 pounds per square inch to 2.5 pounds per square inchgauge during a joint test, regardless of pipe size, shall be twenty (20)seconds.

For sections of pipe less than 36-inch inside diameter, the minimumtime allowable for the pressure to drop from 3.5 pounds per square inchgauge to 2.5 pounds per square inch gauge must be computed by thefollowing equation:

T = 0.0850 (D)(K)/(Q), where

T = time for pressure to drop 1.0 pounds per square inchgauge in seconds;

K = 0.000419(D)(L), but not less than 1.0 D = nominal inside diameter in inches; L = length of line of same pipe size in feet; and Q = rate of loss, assume 0.0015 cubic feet per minute per

square foot (ft3/min/ft sq) of internal surface area.

Any drop in pressure, from 3.5 psig to 2.5 psig, in a time less than thatrequired by the above formula shall be cause for rejection. When theline tested includes more than one size of pipe, the minimum time shallbe that calculated for the largest size pipe included.

Manholes must be tested separately and independently. All manholesmust be hydrostatically tested with a maximum loss allowance of 0.025gallon per foot diameter per foot of head per hour.

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When lines are air tested, manholes are to be tested separately byexfiltration or vacuum method (see Item SS506, Manholes).

(f) Deflection Test

Deflection tests shall be performed by the Contractor on all flexible andsemi-rigid wastewater pipes. The tests shall be conducted after the finalbackfill has been in place at least 30 days. Testing for in-place deflectionshall be with a pipe mandrel or rigid ball sized at 95% of the inside diameterof the pipe. A second test of flexible and semi-rigid wastewater pipes 18inch size and larger, also with a pipe mandrel or ball sized at 95% of theinside diameter of the pipe, shall be conducted by the Contractor 30 daysprior to expiration of his warranty on the Work.

Contractor shall submit his proposed pipe mandrels or testing balls to theE/A or his designated representative for concurrence prior to testing the line.

Test(s) must be performed without mechanical pulling devices and must bewitnessed by the E/A or his designated representative.

Any deficiencies noted shall be corrected by the Contractor and the test(s)shall be redone.

(27) Pressure Pipe Hydrostatic Testing

After the pipe has been installed and backfilled and all service laterals, firehydrants and other appurtenances installed and connected, a pressure test,followed by a leakage test, will be conducted by the City. The City will furnishthe pump and gauges for the tests. The Contractor shall be present and shallfurnish all necessary assistance for conducting the tests. The specified testpressures will be based on the elevation of the lowest point of the line or sectionunder test. Before applying the specified test pressure, all air shall be expelledfrom the pipe. If permanent air vents are not located at all high points, theContractor shall install corporation cocks at such points.

All drain hydrant and fire hydrant leads, with the main 6-inch gate valveopen, the hydrant valve seats closed and nozzle caps open, shall beincluded in the test.

(a) Pressure Test

The entire project or each valved section shall be tested, at a pressure of 200psi for a sufficient period (approximately 10 minutes) to discover allleaking or defective materials. Repairs shall be made by the Contractor tocorrect any leaking or defective materials.

(b) Pressure Pipe Leakage Test

A leakage test will follow the pressure test and be conducted on the entireproject or each valved section. The leakage test shall be at 150 psi for atleast 1 hour.

(1) Allowable Leakage

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Leakage shall be defined as the quantity of water that must be suppliedinto any test section of pipe to maintain the specified leakage testpressure (see above, "Pressure Pipe Leakage Test") after the air in thepipeline has been expelled and the pipe has been filled with water.

No pipe installation will be accepted if the leakage exceeds 25 gallons/24hours/mile of pipe/inch nominal pipe diameter.

( 25 gpd ) (in. - mi.)

(2) Location and Correction of Leakage

If such testing discloses leakage in excess of this specified allowable, theContractor, at his expense, shall locate and correct all defects in the pipeline until the leakage is within the indicated allowance.

All visible leakage in pipe shall also be corrected by Contractor at hisown expense.

(28) Service Charges for TestingInitial testing performed by City forces for the Contractor will be at the City'sexpense. Retesting, by City forces, of Contractor's work that fails initial testingwill be at the Contractor's expense. The City’s charge for retests will be $265.00,plus $50.00 for each hour over four hours. On City-funded projects, the chargesincurred by the City for retesting will be deducted from funds due theContractor. On non-City-funded projects, the charges incurred by the City forretesting will be billed to the Contractor. The City will withhold acceptance ofthe Contractor's work until the Contractor has paid the City for the retestingcosts.

(29) Disinfection of Potable Water LinesThe Contractor shall protect all piping materials from contaminationduring storage, handling and installation. Prior to disinfection, the pipelineinterior shall be clean, dry and unobstructed. All openings in the pipelineshall be closed with watertight plugs when pipe laying is stopped at theclose of the day’s work.

Water for the Work shall be metered and furnished by the Contractor inaccordance with Section 01500 of the Standard Contract Documents.

The Contractor, at its expense, will supply the test gauges and the SodiumHypochlorite conforming to ANSI/AWWA B300, which contains approximately5 percent to fifteen percent available chlorine, and will submit for approval awritten plan for the disinfection process. Calcium Hypochlorite conforming toANSI/AWWA B300, which contains approximately 65 percent available chlorineby weight, may be used in granular form or in 5 g tablets for 16” diameter orsmaller lines, if it is included as part of the written plan of disinfection that isapproved by the City of Austin. The Contractor, at its expense, shall provide all

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other equipment, supplies and the necessary labor to perform the disinfectionunder the general supervision of the City.

(a) Procedure and Dosage

One connection to the existing system will be allowed with a valve arrangedto prevent the strong disinfecting dosage from flowing back into the existingwater supply piping. The valve shall be kept closed and locked in a valve boxwith the lid painted red. No other connection shall be made until thedisinfection of the new line is complete and the water samples have met theestablished criteria. The valve shall remain closed at all times except whenfilling or flushing the line and must be manned during these operations.Backflow prevention must be provided if the valve is left unattended. Thenew pipeline shall be filled completely with disinfecting solution by feedingthe concentrated chlorine and approved water from the existing systemuniformly into the new piping in such proportions that every part of the linehas a minimum concentration of 50 parts per million (50 ppm or 50 mg/liter)available chlorine.

Unless otherwise indicated, all quantities specified herein refer tomeasurements required by the testing procedures included in the currentedition of "Standard Methods". The chlorine concentration at each step in thedisinfection procedure shall be verified by chlorine residual determinations.The disinfecting solution shall be retained in the piping for at least 24 hoursand all valves, hydrants, services, stubs, etc. shall be operated so as todisinfect all their parts. After this retention period, the water shall contain noless than 25 parts per million chlorine throughout the treated section of thepipeline.

The heavily chlorinated water shall then be carefully flushed from the potablewater line until the chlorine concentration is no higher than the residualgenerally prevailing in the existing distribution system or approximately onepart per million. Proper planning and appropriate preparations in handling,diluting, if necessary, and disposing of this strong chlorine solution isnecessary to insure that there is no injury or damage to the public, the watersystem or the environment. The plans and preparations of the Contractor mustbe approved by the City before flushing of the line may begin. Additionallythe flushing must be witnessed by an authorized representative of the City.

Approval for discharge of the diluted chlorine water or heavily chlorinatedwater into the wastewater system must be obtained from the Water andWastewater Utility Department. The line flushing operations shall beregulated by the Contractor so asnot to overload the wastewater system or cause damage to the odor feedsystems at the lift stations. The City shall designate its own representative tooversee the work.Daily notice of line discharging must be reported to the Water andWastewater Utility Dispatch office.

(b) Bacteriological Testing

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After final flushing of the strong disinfecting solution, water samples fromthe line will be tested for bacteriological quality by the City and must befound free of coliform organisms before the pipeline may be placed inservice. One test sample will be drawn from the end of the main andadditional samples will be collected at intervals of not more than 1000 feetalong the pipeline. All stubs shall be tested before connections are made toexisting systems.

The Contractor, at its expense, shall install sufficient sampling taps at properlocations along the pipeline. Each sampling tap shall consist of a standardcorporation cock installed in the line and extended with a copper tubinggooseneck assembly. After samples have been collected, the gooseneckassembly may be removed and retained for future use.

Samples for bacteriological analysis will only be collected from suitablesampling taps in sterile bottles treated with sodium thiosulfate. Samples shallnot be drawn from hoses or unregulated sources. The City, at its expense, willfurnish the sterile sample bottles and may, at its discretion, collect the testsamples with City personnel.

If the initial disinfection fails to produce acceptable sample test results, thedisinfection procedure shall be repeated at the Contractor’s expense. Beforethe piping may be placed in service, satisfactory test results must be obtained.

An acceptable test sample is one in which: (1) the chlorine level is similar tothe level of the existing distribution system; (2) there is no free chlorine and(3) the total coliform count is zero. An invalid sample is one, which hasexcessive free chlorine, silt or non-coliform growth as defined in the currentissue of the "Standards Methods.” If invalid sample results are obtained forany pipe, the Contractor may, with the concurrence of the Inspector, flush thelines and then collect a second series of test samples for testing by the City.After this flushing sequence is completed, any pipe with one or more failedsamples must be disinfected again in accordance with the approveddisinfection procedure followed by appropriate sampling and testing of thewater.

The City of Austin Water Quality Laboratory will notify the assigned City ofAustin Inspector in writing of all test results. The Inspector will subsequentlynotify the Contractor of all test results. The Water Quality Laboratory willnot release test results directly to the Contractor.

(30) Cleanup and Restoration

It shall be the Contractor's responsibility to keep the construction site neat, cleanand orderly at all times. Cleanup shall be vigorous and continuous to minimizetraffic hazards or obstructions along the streets and to driveways. Trenching,backfill, pavement repair (as necessary), and cleanup shall be coordinated asdirected by the City. The E/A will regulate the amount of open ditch and mayhalt additional trenching if cleanup is not adequate to allow for orderly trafficflow and access.

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Materials at the site shall be stored in a neat and orderly manner so as not toobstruct pedestrian or vehicular traffic. All damaged material shall be removedfrom the construction site immediately and disposed of in a proper manner. Allsurplus excavated materials become the property of the Contractor for disposal athis expense. After trenching, the Contractor shall immediately remove allexcavated materials unsuitable for or in excess of, backfill requirements.Immediately following the pipe laying Work as it progresses, the Contractor shallbackfill, grade and compact all excavations as provided elsewhere and shallimmediately clean up and remove all unused soil, waste and debris and restore allsurfaces and improvements to a condition equal or superior to that beforeconstruction began and to an appearance which complements the surroundings.The Contractor shall grade and dress the top 6 inches of earth surfaces with soilor other material similar and equal to the surrounding, fill and smooth any visibletracks or ruts, replace and re-establish all damaged or disturbed turf or othervegetation and otherwise make every effort to encourage the return of the entiresurface and all improvements to a pleasant appearance and useful conditionappropriate and complementary to the surroundings and equal or similar to thatbefore construction began.

Permanent pavement replacement, if necessary, shall begin immediately after alltesting of each segment of piping is satisfactorily completed.

SS510.4 Measurement and Payment

Work performed and materials furnished as prescribed by this item will be measured andpaid by the appropriate unit bid price identified in TxDOT Special Specification “Waterand Wastewater Utilities”.

A "W" after the pay item indicates the use for water.A "WW" after the pay item indicates the use for wastewater.

End

Applicable References:

Standard Specifications Manual: Item Nos. Ref: 102S, 210, 402, 403, 501, 502, 505,506, 507, 509, 593, 601, 604

Standards Manual: Standard Detail Nos. 510-1, (520 - series).

Design Criteria Manuals: Utilities, Section 5.

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Item No.SS511Water Valves

SS511.1 Description

This item shall govern the valves furnished and installed as indicated on theDrawings. Unless otherwise indicated on the Drawings, all valves 4 inches (102mm) and larger shall be AWWA-type valves of suitable design and fullyequipped for service buried in the earth, without need for further modificationand shall be wrapped with 8-mil (0.2 mm) polyethylene film with all edges andlaps securely taped to provide a continuous wrap. Where not indicated, theContractor may use valves with any type end-joint allowed for fittings of the pipeclass being used. Unless otherwise indicated on the Drawings, all valve stemsshall be adjusted to situate the operating nut not more than 24 inches (0.6 meters)below the proposed ground or paving surface of the finished project.

This specification is applicable for projects or work involving either inch-poundsor SI units. Within the text, inch-pound units are given preference followed by SIunits shown within parentheses.

SS511.2 Materials

The Contractor shall submit descriptive information and evidence that thematerials and equipment the Contractor proposes for incorporation in the Work isof the kind and quality that satisfies the specified functions and quality. The Cityof Austin Water and Wastewater Utility Standard Products Lists (SPL) areconsidered to form a part of these Specifications. Contractors may, whenappropriate, elect to use products from the SPL; however, submittal to theEngineer/Architect (E/A) is still required. If the Contractor elects to use anymaterials from these lists, each product shall be completely and clearly identifiedby its corresponding SPL number when making the product submittal. This willexpedite the review process in which the E/A, and, if necessary, the Water andWastewater Utility Standard Products Committee, decide whether the productsmeet the Contract requirements and the specific use foreseen by the E/A in thedesign of this engineered Project.

The SPL’s should not be interpreted as being a pre-approved list of productsnecessarily meeting the requirements for a given construction Project. Itemscontained in the SPL cannot be substituted for items shown on the Drawings, orcalled for in the specifications, or specified in the Bidding Requirements,Contract Forms and Conditions of Contract, unless approved by the E/A inconjunction with the Water and Wastewater Utility Standard ProductsCommittee. The Standard Product List current at the time of plan approval willgovern.

(A) Samples, Inspection and Testing Requirements:

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All tests and inspections called for by the applicable standards shall beperformed by the manufacturer. Upon request, results of these tests shall bemade available to the purchaser.

(B) Other Requirements:

Each submittal shall be accompanied by:

(1) Complete data covering:

a). the operator, including type and size, model number, etc.,

b). the manufacturer's name and address of his nearest service facility,

c). the number of turns to fully open or close the valve.

(2) detailed instructions for calibrating the limit stops for open and closedpositions, and

(3) any other information which may be necessary to operate and maintainthe operator.

(4) Complete dimensional data and installation instructions for the valveassemblyas it is to be installed, including the operator.

(5) Complete replacement parts lists and drawings, identifying every partfor both the valve and operator.

SS511.3 Valves

(A) Iron-Body Gate Valves

Unless otherwise indicated, Iron Body Gate Valves, 4" to 12" (102 mm to305 mm), including Tapping Valves, shall conform to AWWA C509,"Resilient Seated Gate Valves for Water and Sewerage Systems".

Iron Body Gate Valves larger than 12" (305 mm), including Tapping Valves,shall be double disc, parallel seat valves meeting the requirements ofAWWA C500.

16“ (406 mm) Iron Body Resilient Seated Gate valves may be used if calledfor in the design and if indicated in the Standard Product List WW-282.

(1) Stem Seals: All valves shall have approved O-ring type stem seals. Atleast two O-rings shall be in contact with the valve stem where itpenetrates the valve body.

(2) Operation: All valves shall have non-rising stems with a 2" (50 mm)square operating nut, or with a spoke type handwheel when so ordered,turning clockwise to close.

(3) Gearing: Double disc gate valves in 16 inch (406 mm) and larger sizesshall be geared and, when necessary for proper bury depth and cover,

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shall be the horizontal bevel-geared type enclosed in a lubricated gearcase.

(4) Bypass: Unless otherwise indicated, 16 inch (406 mm) and larger gatevalves shall be equipped with a bypass of the non-rising stem type whichmeets the same AWWA standard required for the main valve.

(5) Valve Ends: Valve ends shall be push-on, flanged or mechanical joint, asindicated or approved.

Tapping valves shall have inlet flanges conforming to MSS SP-60, withbolt holes drilled per ANSI B16.1 Class 125. Seat rings and body castingshall be over-sized as required to accommodate full size cutters; the outletend shall be constructed and drilled to allow the drilling machine adapterto be attached directly to the valve.

(6) Gear Case: All geared valves shall have enclosed gear cases of theextended type, attached to the valve bonnet in a manner that makes itpossible to replace the stem seal without disassembly and withoutdisturbing the gears, bearing or gear lubricant. Gear cases shall bedesigned and fabricated with an opening to atmosphere so that waterleakage past the stem seal does not enter the gear case.

(7) Valve Body: Double disc gate valves in 16 inch (406 mm) and largersizes installed in the horizontal position shall have bronze rollers, tracks,scrapers, etc.

(B) Butterfly Valves:

Unless otherwise indicated, all valves shall conform to the current "AWWA"Standard C-504, "Rubber-Seated Butterfly Valves", Class 150B, except asmodified or supplemented herein.

(1) Functional Requirements

a). Valves shall be the short body design and shall have flangedconnections on both ends unless otherwise called for.

b). Valves shall be of such design that the valve discs will not vibrate orflutter when operated in a throttled position. Valve discs shall besecured to the shafts by means of keys or pins so arranged that thevalve discs can be readily removed without damage thereto. Allkeys and pins used in securing valve discs to shafts shall be stainlesssteel or monel. Valve discs shall be stainless steel or ductile iron,ASTM A 536, Grade 65-45-12 (448-310-12); seating edge shall bestainless steel or other corrosion resistant material.

c). Valve shafts shall be constructed of wrought stainless steel or monel.The ends of the shaft shall be permanently marked to indicate theposition of the disc on the shaft.

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d). All buried valves shall have approved manufacturer's O-ring type orsplit V type "Chevron" shaft seals. When O-ring seals are used,there shall be at least two O-rings in contact with the valve shaftwhere it penetrates the valve body.

On 24 inch (635 mm) and larger valves, the seat shall be completelyreplaceable and/or adjustable with common hand tools withoutdisassembling the valve from the pipeline.

Rubber seats located on the valve disc shall be mechanically securedwith stainless steel retainer rings and fasteners.

e). Unless otherwise indicated, valves shall be provided with manualoperators with vertical stems and 2 inches (50 mm) square operatingnut turning clockwise to close and equipped with a valve discposition indicator. All keys or pins shall be stainless steel or monel.Buried valves shall have the valve stems extended or adjusted tolocate the top of the operating nut no more than 24 inches (0.6meter) below finish grade.

f). Unless otherwise indicated, motorized butterfly valves shall beequipped with 230/460 volt, 3-phase reversing motor operators,extended as required to locate the center line of the operator shaftapproximately 4 feet to 4 feet, 6 inches (1.2 to 1.4 meters) abovefinish grade. Operators shall be equipped with cast iron ormalleable iron manual override hand wheel with a valve positionindicator, local push button controls, lighted status/positionindicator, torque and travel limit switches and all switches, relaysand controls (except external power and signal wiring) necessary forboth local and remote operation.

(2) Performance Requirements

a). Unless otherwise indicated, valve operators shall be sized to seat,unseat, open and close the valve with 150 psi (1 megapascal) shutoffpressure differential across the disk and allow a flow velocity of 16feet (4.9 meters) per second past the disc in either direction.

b). Motorized valve motors shall be capable of producing at least 140percent of the torque required to operate the valves under conditionsof maximum non-shock shutoff pressure without exceeding apermissible temperature rise of 1310F over 1040F ambient (55degrees Celsius over 40 degrees Celsius ambient); they shall have aduty rating of not less than 15 minutes and shall be capable ofoperating the valve through 4 1/2 cycles against full unbalancedpressure without exceeding the permissible temperature rise. Motorsshall be suitable for operating the valve under maximum differentialpressure when voltage to motor terminals is 80 percent of nominalvoltage. Motor bearings shall be permanently lubricated and sealed.

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(C) Ball Valves:

Ball valves shall be brass, bronze, stainless steel or PVC as indicated on theDrawings or Details or as approved by the Engineer.

(D) Air-Vacuum Release Valves

(1) Valves shall be combination air-release, air-vacuum units havingsmall and large orifice units contained and operating within a singlebody or assembled unit.

The small orifice system shall automatically release small volumes ofair while the pipe is operating under normal conditions. The large air-vacuum orifice system shall automatically exhaust large volumes ofair while the pipe is being filled and shall permit immediate re-entryof air while being drained.

Valves shall be rated for at least 150 psi (1 megapascal) {maximum}normal service pressure.

(2) Material Requirements

Valve exterior bodies and covers shall be cast iron.

Internal bushings, hinge pins, float guide and retaining screws, pins,etc., shall be stainless steel or bronze.

Orifice seats shall be Buna-N rubber.

Floats shall be stainless steel, rated at 1000 psi (6.9 megapascals).

Unless otherwise indicated, these valves shall be as included in theStandard Products List (SPL WW-367 for water, WW-462 forwastewater force mains).

(E) Fire Hydrants

All fire hydrants shall be Dry Barrel, Traffic Model (break-away), Post Typehaving Compression Type Main Valves with 5 1/4" (133 mm) opening,closing with line pressure. Approved models are listed on SPL WW-3 of theWater and Wastewater Utility Standard Products List.

(1) Applicable Specifications

AWWA C-502 current: "AWWA Standard for Dry-Barrel FireHydrants".

NFPA 1963: "National (American) Standard Fire Hose Coupling ScrewThread" and City of Austin 4 inch (102 mm) Fire Hose ConnectionStandard (Available upon request from Standards Committee Secretaryat 322-2806).

ANSI A-21.11 current: "American National Standard for Rubber GasketJoints for Cast Iron and Ductile Iron Pressure Pipe and Fittings".

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(2) Functional Requirements

Design Working Pressure shall be 200 psi (1.38 megapascals) and a testpressure of 400 psi (2.76 megapascals).

Inlet shall be side connection hub end for mechanical joint (ANSI A-21.11-current). Shoe shall be rigidly designed to prevent breakage.

Lower Barrel shall be rigid to assure above ground break at trafficfeature. Bury length of hydrant shall be four (4) feet (1.2 meters)minimum, five (5) feet (1.5 meters) maximum (hydrant lead pipe may beelbowed up from main using restrained joints; flanged joints in leadpipes are not allowed). Flange type connections between hydrant shoe,barrel sections and bonnet shall have minimum of 6 corrosion resistantbolts.

Hydrant Main Valve shall be 5 1/4 inch (133 mm) I.D. Valve stemdesign shall meet requirements of AWWA C502, with Operating Nutturning clockwise to close. Operating Nut shall be pentagonal, 1 1/2inch (38 mm) point to flat at base, and 1 7/16 inches (36.5 mm) at topand 1 inch (25 mm) minimum height. Seat ring shall be bronze (bronzeto bronze threading), and shall be removable with light weight stemwrench. Valve mechanisms shall be flushed with each operation ofvalve; there shall be a minimum of two (2) drain ports.

Traffic Feature shall have replaceable break-away ferrous metal stem-coupling held to stem by readily removable type 302 or 304 stainlesssteel fastenings. Break-away flange or frangible lugs shall be designedto assure above-ground break. Break-away or frangible bolts will not beacceptable.

Outlet Nozzles shall be located approximately 18 inches (450 mm) aboveground. Each hydrant shall have two (2) 2 1/2 inch (63.5 mm) nozzles180 degrees apart with National (American) Standard Fire HoseCoupling Screw Thread NFPA 1963 and one (1) 4 inch (102 mm)pumper nozzle with City of Austin standard thread–six (6) threads perinch (25 mm) "Higbee" cut, 4.8590 inch (123.4 mm) O.D., 4.6425 inch(117.9 mm) root diameter. Nozzles shall be threaded or cam-locked, O-ring sealed, and shall have type 302 or 304 stainless steel lockingdevices. Nozzle caps (without chains) and cap gaskets shall be furnishedon the hydrant. The cap nut shall have the same configuration as theoperating nut.

Hydrants shall be Dry-Top Construction, factory lubricated oil or greasewith the lubricant plug readily accessible. The system shall be describedfor City approval.

A blue reflective delineator of a type approved by the Engineer shall beplaced 2 to 3 feet (0.6 to 0.9 meters) offset from the centerline of pavedstreets, on the side of and in line with, all newly installed fire hydrants.

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Hydrant shall have double O-ring seals in a bronze stem sheath housingto assure separation of lubricant from water and shall have a weather capor seal, or both, as approved by the Owner, to provide complete weatherprotection.

(3) Material Requirements

All below ground bolts shall be corrosion resistant. The hydrant valveshall be Neoprene, 90 durometer minimum. The seat ring, drain ring,operating nut and nozzles shall be bronze, AWWA C-502 current,containing not over 16 percent zinc. Break-away stem coupling shall beof ferrous material; its retaining pins, bolts, nuts, etc. of type 302 or 304stainless steel.

Coatings shall be durable and applied to clean surfaces. Exteriorsurfaces above ground shall receive a coating of the type and colorspecified in the applicable version of City of Austin SPL WW-3. Thecoating shall be applied according to coating manufacturer'sspecifications. Other exposed ferrous metal shall receive asphalt-basedvarnish, or approved equal, applied according to the coatingmanufacturer's specifications.

(F) Pressure/Flow Control Valves:

All control valves to regulate pressure, flow, etc., in City lines shall bemodels listed in the City of Austin Water and Wastewater Standard ProductsList (SPL).

(G) Drain Valves:

Drain valve materials and installation shall conform to City of AustinStandard Detail No. 511-9/511S-9.

SS511.4 Construction Methods

(A) Setting Valves, Drains and Air Releases

Unless otherwise indicated, main line valves, drain valves and piping, air andvacuum release assemblies and other miscellaneous accessories shall be setand jointed in the manner described for cleaning, laying, and jointing pipe.

Unless otherwise indicated, valves shall be set at the locations shown on theDrawings and such that their location does not confict with otherappurtenances such as curb ramps. Valves shall be installed so that the topsof operating stems will be at the proper elevation required for the piping atthe location indicated above. Valve boxes and valve stem casings shall befirmly supported and maintained, centered and aligned plumb over the valveor operating stem, with the top of the box or casing installed flush with thefinished ground or pavement in existing streets, and installed with the top ofthe box or casing approximately 6 inches (150 mm) below the standard streetsubgrade in streets which are excavated for paving construction

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or where such excavation is scheduled or elsewhere as directed by theEngineer or designated representative.

Drainage branches or air blowoffs shall not be connected to any sanitarysewer or submerged in any stream or be installed in any other manner thatwill permit back siphonage into the distribution system (see City of Austin"Standard Detail Drawings- Series 500/500S"). Every drain line and everyair release line shall have a full sized independent gate valve flanged directlyto the main. Flap-valves, shear gates, etc., will not be accepted.

(B) Setting Fire Hydrants:

Fire hydrants shall be located in a manner to provide accessibility and insuch a manner that the possibility of damage from vehicles or conflict withpedestrian travel will be minimized. Unless otherwise directed, the settingof any hydrant shall conform to the following:

Hydrants between curb and sidewalk on public streets, shall be installed asshown on Standard 511-17/511S-17, with outermost point of large nozzlecap 6" to 18" (150 mm to 450 mm) behind back of curb. Where walk abutscurb, and in other public areas or in commercial areas, dimension fromgutter face of curb to outermost part of any nozzle cap shall be not less than3 feet (0.9 meters), nor more than 6 feet (1.8 meters), except that no part of ahydrant or its nozzle caps shall be within 6 inches (150 mm) of any sidewalkor pedestrian ramp. Any fire hydrant placed near a street corner shall be noless than 20 feet (6 meters) from the curb line point of tangency. Firehydrants shall not be installed within nine feet (2.75 meters) vertically orhorizontally of any sanitary sewer line regardless of construction.

All hydrants shall stand plumb; those near curbs shall have the 4 inch (102mm) nozzle facing the curb and perpendicular to it. The hydrant bury markshall be located at ground or other finish grade; nozzles of all new hydrantsshall be approximately 18 inches (450 mm) above grade. Lower barrellength shall not exceed 5 feet (1.5 meters). Barrel extensions are notpermitted unless approved by the Engineer. Each hydrant shall be connectedto the main by 6 inch (152 mm) ductile iron pipe; a 6 inch (152 mm) gatevalve shall be installed in the line for individual shutoff of each new hydrant.

Below each hydrant, a drainage pit 2 feet (0.6 meter) in diameter and 2 feet(0.6 meter) deep shall be excavated and filled with compacted coarse gravelor broken stone mixed with coarse sand under and around the bowl of thehydrant, except where thrust blocking is situated (City of AustinSpecification Item 510/SS510 and Standard Detail 510-6/510S-6) and to alevel 6 inches (150 mm) above the hydrant drain opening. No hydrantdrainage pit shall be connected to a sanitary sewer. Cover drain gravel withfilter fabric to prevent blockage of voids in the gravel by migration ofbackfill material. The bowl of each hydrant shall be well braced againstunexcavated earth at the end of the trench with concrete thrust blocking(taking care not to obstruct the hydrant drain holes), or the hydrant shall be

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tied to the pipe with approved metal harness rods and clamps, or the valveand lateral between the main and the hydrant may be restrained withapproved restrained joints of pipe. Hydrants shall be thoroughly cleaned ofdirt or foreign matter before setting.

Fire hydrants on mains under construction shall be securely wrapped with apoly wrap bag or envelope taped into place. When the mains are acceptedand placed in service the bag shall be removed.

(C) Pressure Taps: Refer to Item No. 510.3 (24)/510S.3 (24), "Pipe".

(D) Plugging Dead Ends:

Standard plugs shall be inserted into the bells of all dead ends of pipes, teesor crosses and spigot ends shall be capped. All end plugs or caps shall besecured to the pipe conforming to C.O.A. Special Specification Item No.SS510.3 (22)/510S.3 (22), "Pipe".

(E) Protective Covering:

Unless otherwise indicated, all flanges, nuts, bolts, threaded outlets and allother steel component shall be coal tar coated and shall be wrapped withstandard minimum 8-mil (0.2 mm) low density polyethylene film or aminimum 4-mil (0.1 mm) cross laminated high-density polyethylenemeeting ANSI/AWWA Specification C-105-current, with all edges and lapstaped securely to provide a continuous and watertight wrap. Repair allpunctures of the polyethylene, including those caused in the placement ofbedding aggregates, with duct tape to restore the continuous protective wrapbefore backfilling.

(F) Valve Box, Casing and Cover:

Stems of all buried valves shall be protected by valve box assemblies. Valvebox castings shall conform to ASTM A 48, Class 30B. Testing shall beverified by the manufacturer at the time of shipment. Each casting shall havecast upon it a distinct mark identifying the manufacturer and the country oforigin.

(G) Drain Valve Installations: Refer to City of Austin Standards 511-9/511S-9.

(H) Air Release Assemblies: Refer to City of Austin Standards 511-1/511S-1,511-2/511S-2, and 511-3/511S-3.

(I) Pressure/Flow Control Valves: Assemblies shall be installed as indicated.

(J) Connections to Existing System: Refer to Item No. 510/SS510, "Pipe" forconnections to the existing system.

(K) Shutoffs: Refer to Item No. 510/SS510, "Pipe" for shutoffs.(L) Abandoned Fire Hydrants

After all new water utilities for this project have been installed, tested andapproved, and while existing water mains for this project are being retired,

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existing fire hydrants connected to these abandoned mains shall be removedand properly disposed.

SS511.5 Measurement and Payment

All types of valves, fire hydrants, drain valves, pressure/Flow control valveassemblies, manual and automatic air release assemblies, and all incidental andsubsidiary materials necessary to complete the work will be measured and paid forby appropriate bid item in accordance with TxDOT Special Specification, “Waterand Wastewater Utilities”, under “Measurement” and “Payment” sections.

END

SPECIFIC CROSS REFERENCE MATERIALSSpecial Specification SS511, “Water Valves”

City of Austin Special Specification ItemsDesignation DescriptionItem No. SS510 Pipe

City of Austin Standard DetailsDesignation Description511S-1 1” (25 mm) –2” (76 mm) Air Release Valve Installation

(Type I)511S-2 3” (76 mm) or Larger Air/Vacuum Valve Installation

(Type II)511S-3 3” (76 mm) or Larger Air/Vacuum Valve Installation

(Type III)511S-9 Drain Valve Installation511S-17 Standard Fire Hydrant Installation

20. City of Austin Standard ProductsDesignation DescriptionWW-3 Standard Products List for Fire HydrantsWW-282 Standard Products List for Valves, Gate, Resilient SeatedWW-367 Standard Products List for Air Release Valves, WaterWW-462 Standard Products List for Air Release Valves,

Wastewater

ANSI/AWWA StandardsDesignation DescriptionA-21.11 American National Standard for Rubber Gasket Joints for

Cast Iron and Ductile Iron Pressure Pipe and FittingsC-105 American National Standard for Polyethylene

Encasement for Ductile-Iron PipeC-500 Metal-Seated Gate Valves for Water Supply ServiceC-502 Dry-Barrel Fire HydrantsC-504 Rubber-Seated Butterfly Valves

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C509 Resilient Seated Gate Valves for Water and SewerageSystems

ASTM StandardsDesignation DescriptionASTM A48/A48M Specification for Gray Iron Castings

ASTM A 536 Specification for Ductile Iron CastingsNational Fire Protection Association (NFPA)1963 National (American) Standard Fire Hose Coupling Screw Thread

RELATED CROSS REFERENCE MATERIALSSpecial Specification 511S, “Water Valves”

City of Austin Standard Specification ItemsDesignation DescriptionItem No. 501 Jacking or BoringItem No. 502 TunnelingItem No. 503 Frames, Grates, Rings and CoversItem No. 505 Concrete Encasement and Encasement PipeItem No. 506 ManholesItem No. 507 BulkheadsItem No. 508S Miscellaneous Structures and AppurtenancesItem No. 509 Trench Safety Systems

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Item No. SS509STrench Safety Systems

S509S.1 Description

This item shall govern the following:

A. Designing, furnishing, and installing a Trench Safety System for trenchexcavation;

B. Dewatering the area as specified on the Drawings and/or required; and

C. Maintenance and removal of the trench safety systems as determined byContractor's Trench Safety Engineer and/or Contractor's CompetentPerson(s).

This Item also includes special clearing, excavation and backfilling for safetysystems. At a minimum, this work shall conform to United States Department ofLabor Rules 29 CFR, Part 1926 Occupational Safety and Health Administration(OSHA). The Competent Person(s) shall be on the project whenever workers are inan excavation trench.

This specification is applicable for projects or work involving either SI or inch-pound units. Within the text, the SI units are given preference followed by inch-pound units shown within parentheses.

S509S.2 Trench Safety System Plan Submittal

Prior to, or at the Pre-Construction Conference, the Contractor shall submit to theOwner a Trench Safety System Plan sealed by a registered Professional Engineerlicensed in the State of Texas. Notice To Proceed with construction will not beissued by the Owner until the Contractor has submitted a Trench Safety SystemPlan to the Owner.

The Trench Safety System Plan at a minimum shall conform to OSHA standards forsloping of sides, utilization of trench boxes, and/or utilization of shoring, sheetingand bracing methods. The Contractor shall be responsible for obtaining thegeotechnical information necessary to the design of the Trench Safety System Plan[normally acquired from borings taken at 150 meter (500 foot) intervals along theproposed centerline to a minimum depth of 1.5 meters (five feet) below proposedflowline]. If the geotechnical information for the design of the improvements isacquired by the Owner or designated representative, it shall be provided to theContractor for information purposes subject to the provisions of City of AustinStandard Contract Section 00220, "Geotechnical Data".

The Trench Safety System Plan submittal shall include:

A. A Drawing or plan indicating specific designation of areas in which each typeof system will be used, including the length of trench to be opened, the lengthof time that the trench will remain open, the means of egress, the storage of

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materials, allowable loads on trench walls, the methods for placing/compactingbedding/backfill within the safety of the system, any equipment restrictions andthe subsequent removal of system,

B. Drawings or manufacturer's data, as applicable, that describe the variouselements of the Trench Safety System in sufficient detail that the workers canproperly install the Trench Safety System,

C. Recommendations and limitations for using systems.

D. Sealed engineering calculations and/or equipment manufacturer's certifications,as applicable, that confirm that the system is designed to withstand theanticipated loadings and that it can be fully installed/implemented in thedesignated space within the street right of way or easement provided by Owneror designated representative.

E. A Certificate of Insurance of the Trench Safety Engineer's ProfessionalLiability Insurance coverage meeting the requirements of the City of AustinStandard Contact Documents (Section 00020) shall be provided.

F. Certificate of Completion of an OSHA-approved program indicating that theContractor’s Competent Person(s) has received training in “ExcavationSafety”.

S509S.3 Trench Safety System Plan Review

The review of the Trench Safety System Plan that will be conducted by the Owneror designated representative shall only relate to general conformance with OSHAstandards and regulations. The Owner's failure to note exception(s) to the submittalshall not relieve the Contractor of any or all responsibility or liability for the TrenchSafety System Plan. The Contractor shall remain solely and completely responsiblefor all trench safety systems and for the associated means, methods, procedures, andmaterials.

S509S.4 Construction Methods

The Contractor's Competent Person(s) shall be responsible for the maintenance of acopy of appropriate OSHA regulations onsite and the implementation of OSHAtrenching safety regulations at the work site. Trenching shall be completed to thelines and grades indicated on the Drawings or as specified in various technicalstandard specification items requiring excavation and trenching and/or backfilling.The Contractor shall perform all trenching in a safe manner and shall maintainsafety systems to prevent death or injury to personnel or damage to structures,utilities or property in or near excavation.

If evidence of possible cave-ins or earthen slides is apparent or an installed trenchsafety system is damaged, the work in trench shall immediately cease, personnelevacuated from hazardous area and the Owner notified. Personnel shall not beallowed to re-enter the excavation until necessary repairs or replacements are

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completed and are inspected and approved by the Contractor's CompetentPerson(s). Repair and replacement of damaged safety system shall be at theContractor's sole expense.

S509S.5 Changed Conditions

When changed conditions require modifications to the Trench Safety System, theContractor shall provide to the Owner or designated representative a new design oran alternate Trench Safety System that is proposed by the Contractor's TrenchSafety Engineer to address the changed conditions encountered. Copies of the newdesign or alternate system shall be provided to the Owner or designatedrepresentative in accordance with the requirements of section 509S.2 entitled"Trench Safety System Plan Submittal". A copy of the most current Trench SafetySystem shall be maintained on site and made available to inspection andenforcement officials at all times.

Any changes to the Trench Safety System Plan that are initiated by the Contractorfor operational efficiency or as a result of changed conditions, that could bereasonably anticipated, will not be cause for contract time extension or costadjustment. When changes to the Trench Safety System Plan are necessitated bysevere and uncharacteristic natural conditions or other conditions totally out of thecontrol of the Contractor, the Contractor may make a written request to the Ownerfor a Change Order to address the anticipated work. The Contractor shall notify theOwner in writing within 24 hours of the occurrence of changed conditions that theContractor anticipates the submittal of a claim for additional compensation. Under'Changed Conditions" the work deemed immediately necessary by the Contractor toprotect the safety of workers and public, equipment or materials may only beaccomplished until the Owner or designated representative has a reasonableopportunity to investigate the Contractor's written request for a Change Order andrespond in writing to the request.

S509S.6 Measurement and Payment

Work performed and materials furnished as prescribed by this item as indicated shall bemeasured and paid by appropriate bid items in accordance with TxDOT SpecialSpecification entitled "Water and Wastewater Utilities" Sections entitled “Measurement” and “Payment” .

END

SPECIFIC Cross Reference MaterialsSpecial Specification Item No. SS509S, "Trench Safety Systems"

City of Austin Standard Contract DocumentsDesignation DescriptionSection 00020 Invitation for BidsSection 00220 Geotechnical DataSection 00650 Certificate of InsuranceSection 00700, Article 6.11 Safety and Protection

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RELATED Cross Reference MaterialsTexas Department of Transportation Standard SpecificationsFor Construction and Maintenance of Highways, Streets, and BridgesDesignation DescriptionItem 104 Removing ConcreteItem 110 ExcavationItem 402 Trench Excavation Protection

City of Austin Special Specification ItemsDesignation DescriptionItem No. SS402S Controlled Low Strength MaterialItem No. SS501S Jacking or Boring PipeItem No. SS502S TunnelingItem No. SS503S Frames, Grates, Rings and CoversItem No. SS504S Adjusting StructuresItem No. SS505S Concrete Encasement and Encasement PipeItem No. SS506S Manholes

(2) Item No. SS507S BulkheadsItem No. SS510S PipeItem No. SS511S Water ValvesItem No. SS593S Concrete Retards

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Item No. SS512SManhole Rehabilitation

S512S.1 Description

This item shall govern rehabilitation of manholes complete in place and thematerials used therein, including cleaning, interior surface restoration, primingthe prepared surface, and coating. It shall also include furnishing and installingnew rings, covers, and appurtenances as indicated on the Drawings, and anypumping, and drainage necessary to complete the work.

The City of Austin Water and Wastewater Standard Products Lists (SPLs) forma part of these Specifications. The purpose of SPLs is to expedite review ofContractor product submittals by the Engineer or designated representative and,if necessary, the City of Austin Water and Wastewater Utility StandardProducts Committee. The SPLs should not be interpreted as being a pre-approved list of products necessarily meeting the requirements for a givenconstruction Project. Items contained on an SPL cannot be substituted foritems shown on the Drawings or called for in specifications, or specified in theBidding Requirements, Contract Forms and Conditions of the Contract, unlessapproved by the Engineer or designated representative in conjunction with theCity of Austin Water and Wastewater Utility Standard Products Committee.The Standard Product Lists current at the time of plan approval will govern.

The Contractor shall submit descriptive information and evidence that thematerials and equipment the Contractor proposes for incorporation in the Workis of the kind and quality that satisfies the specified functions and quality.Contractors may, when appropriate, elect to use products from the SPL;however, submittal to the Engineer or designated representative is still required.If the Contractor elects to use any materials from these lists, each product shallbe completely and clearly identified by its corresponding SPL number whenmaking the product submittal. This application will expedite the reviewprocess in which the Engineer or designated representative, and, if necessary,the Water and Wastewater Utility Standard Products Committee, decideswhether the products meet the Contract requirements and the specific useforeseen by the Engineer or designated representative in the design of thisengineered Project.

Wastewater manholes shall be acceptance tested by the Contractor.

S512S.2 Submittals

The submittal requirements of this specification item include:

A. Type, size, manufacturer and condition of manhole (diameter of water orwastewater manhole), structure (pre-cast, cast in place; Standard, Tee, etc),and materials and equipment to be furnished (brick, concrete, seals, rings,covers, etc.)

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B. Aggregate types, gradations and physical characteristics for the Portlandcement concrete mix.

C. Proposed proportioning of materials for the mortar mix.D. Proposed Acceptance testing procedure and associated test equipment and

materials Type structures and proposed adjustment technique (lowering,raising, lateral displacement).

E. Equipment and/or methods proposed by the Contractor to determine andverify the thickness of the applied Corrosion Resistant Coating Materials.

Submittal of test Records is required and shall include as a minimum thefollowing items. The test records shall also be included as part of the Projectrecords turned in with the acceptance package.

Name of the manhole manufacturerInterior surface coating type and application method for Wastewater ManholesModel and manufacturer of vacuum testerDate tested/date re-testedPassed/failed and state what was done to correct the problemTest Method UsedLocation/station of manholePre-cast/cast-in- place bottomAny repairs made to the joints.

S512S.3 Materials and Components

A. Concrete and Cement Stabilized Sand:

All concrete shall conform to TxDOT Specification Item No. 421,“Portland Cement Concrete". All structural concrete work shall conformto TxDOT Specification Item No. 420, “Concrete Structures".

All interior surfaces of wastewater manholes shall have a coatingacceptable to the Engineer or designated representative or be otherwiseacceptably protected from the acidic effects of municipal wastewater. AllPortland cement concrete shall be TxDOT Class A or Class D and all pre-cast Portland cement concrete shall be TxDoT Class I as indicated on theDrawings.

Cement stabilized sand for bedding or backfilling, when indicated orrequired on the Drawings, shall contain 112 kilograms of Portland cementper cubic meter (2 bags of Portland Cement per cubic yard). The sandshall meet the requirements for "Fine Aggregate" in Section 421.2 (5) ofTxDOT Specification Item No.421, “Portland Cement Concrete”.

B. Mortar:

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The mortar shall be composed of one part Portland Cement, one partmasonry cement (or 1/4 part hydrated lime), and sand equal to 2-1/2 to 3times the sum of the volumes of the cements and lime used. The sandshall meet the requirements for "Fine Aggregate" as given in Section421.2(5) of TxDOT Specification Item No. 421, “Portland CementConcrete”.

C. Grout: Unless otherwise specified on the Drawings, all grouting shall bedone with non-shrink grout.

1. Non-shrink Grout:

Non-shrink grout shall be furnished as factory premixed requiring onlythe addition of water at the jobsite. Grout shall be mixed in amechanical mixer. The addition of water shall be monitored to insurethat only the amount water that is necessary to produce a flowable groutis used. Proportioning and mixing of the components shall be inaccordance with the manufacturer's recommendations.

2. Epoxy Grout:

Epoxy Grout shall consist of a two component liquid epoxy adhesive ofa viscosity appropriate to the location and application and an inertaggregate filler component. Components shall be packaged separatelyat the factory and field mixed. All proportioning and mixing of thecomponents shall be in accordance with the manufacturer'srecommendations.

D. Reinforcement:

The reinforcing steel shall conform to the requirements of TxDOTSpecification Item No. 440, “Reinforcing Steel”. Secondary, non-structural, steel in cast-in-place stormwater manholes may be replacedwith collated fibrillated polypropylene fibers, if approved by the Engineeror designated representative.

E. Brick:

Replacement brick for ring adjustment courses shall be of first quality,sound, hard burned, new perfectly shaped brick conforming to therequirements of ASTM C 62 Grade SW or concrete brick meeting therequirements of ASTM C 55, Grade N-1.

F. Rings and Covers:

Rings and covers shall conform to the requirements of City of AustinSpecial Specification Item entitled “Frames, Grates, Rings and Covers”.All manholes except those located in paved areas shall have bolted covers.

1. Replacement Rings and Covers, 24 in. Diameter Lids:

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This ring and cover shall be used for the replacement of broken ringsand covers, minor manhole adjustment, or as otherwise directed by theEngineer or designated representative.

2. Rings and Covers, 32 in. Diameter Lids:

Unless directed otherwise by the Engineer or designated representative,this ring and cover shall be used for all manhole rehabilitation thatrequire replacement of the cone section.

G. Bulkheads:

Bulkheads shall meet the requirements of City of Austin SpecialSpecification Item entitled “Bulkheads”.

H. Pre-cast Base Sections, Riser Sections, and Cones:

Pre-cast concrete base sections, riser sections, and cones shall conform tothe requirements of ASTM C-478. The width of the invert shall bespecifically sized for the connecting pipes. Inverts shall be “U” shapedwith a minimum depth of three fourths of the largest pipe diameter. Theinvert shall have a minimum difference of 0.10 feet between the inlet andoutlet. Where lines enter the manhole at a location 24 inches or less abovethe flowline of the outlet, the invert shall be filleted to prevent splashingand solids deposition.

A drop pipe shall be provided for a sewer entering a manhole at a locationmore than 24 inches above the flowline of the outlet. Joints for wastewaterbase sections, riser sections, and cones shall conform to the requirementsof ASTM C-443. Additionally, joint dimensions for 48-inch insidediameter wastewater manhole sections and cones shall comply with City ofAustin Standard Detail No. 506S-12, “ O-Ring Joint Detail Pre-castManhole Section” or City of Austin Standard Detail No. 506S-13, “WedgeSeal Joint Detail, Pre-cast Manhole Section”. Precast bases for 48 inchinside diameter manholes shall have preformed inverts.

Inserts acceptable to the Engineer or designated representative shall beembedded in the concrete wall of the manhole sections to facilitatehandling; however, through-wall holes for lifting will not be permitted.Any voids between the pipe and boot shall be filled to the springline with aproduct recommended by the manhole manufacturer to prevent solidscollection.

I. Precast Grade Rings:

Rings shall be reinforced TxDOT Class A Portland cement concrete.

1. Precast Grade Rings, 24-1/2 inches Inside Diameter:

This adjustment ring shall be used only for adjusting existing manholeswith 24 inch lids and for Wastewater Access Device. Inside to outsidediameter dimension of ring shall be 6 inches with a thickness of 3inches to 6 inches.

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2. Precast Grade Rings, 35 inches Inside Diameter:

This adjustment ring shall be used for all new manhole constructionwith 32 inches lids. Inside to outside diameter dimension of ring shallbe 6 inches with a thickness of 4 inches to 6 inches.

J. Corrosion Resistant Coating Materials:

The interior surface of rehabilitated manhole shall be coated with one ofthe following, or other approved products listed in City of Austin Waterand Wastewater Utility SPL No. WW-511:

1. Strong Seal MS2C - 12.5 mm (1/2 inch) minimum thickness.2. FOSROC, Epoxy Chemical and Abrasion Resistant Epoxy Mortar

Liner 1/2 inch minimum thickness.

Equipment and/or methods proposed by the Contractor to determine andverify the thickness of the applied Corrosion Resistant Coating Materialsshall be approved by the Engineer or designated representative.

The surface shall be primed in accordance with the coating manufacturer'srecommendations.

Surface preparation for areas of "touch-up" shall be in accordance with themanufacturer's recommendations.

K. New Manhole Construction and Minor Manhole Adjustment:

New manhole construction and minor manhole adjustments shall beperformed as indicated on City of Austin Standard Detail 506S-4, “NewManhole Construction and Minor Manhole Adjustment”, and shall consistof adding pre-cast reinforced concrete rings to adjust the manhole to finalgrade.

For new manhole construction, the maximum vertical allowable ringadjustment, including the depth of the ring casting, shall be limited to 18inches. For existing manhole adjustments that fall within the limits ofoverlay and street reconstruction projects, the maximum verticalallowable, including the depth of the ring casting, shall be limited to twofeet. All other existing manholes shall have a maximum allowable ringadjustment, including the depth of the ring casting, of one foot. Anyadjustment that will exceed these requirements shall be accomplished asindicated on City of Austin Standard Detail 506S-2, and as describedbelow in subsection (N) “Major Manhole Adjustment”. All manholes notlocated in paved areas shall have bolted covers.

L. Major Manhole Adjustment:

Any adjustment that exceeds the requirements of subsection (M) MinorManhole Adjustments, shall be accomplished as indicated on City ofAustin Standard Detail 506S-2, “Major Manhole Adjustment”, and shall

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consist of any combination of removing the concrete rings, and/or themanhole cone section, and/or the straight riser section of the manhole inorder to bring the manhole to final grade. All manholes not located inpaved areas shall have bolted covers.

M. Waterproofing Joint Materials:

O-rings and wedge seals for the joints of all wastewater manholes, and forstormwater manholes, when indicated on the Drawings, shall conform tothe requirements of ASTM C443. Cold applied preformed plastic gasketsfor stormwater manholes shall be as specified in City of Austin SpecialSpecification Item entitled “Pipe”. Connections between reinforcedconcrete wastewater manhole structures and pipes shall meet therequirements of ASTM C923.

S512S.4 Construction Methods

All interior surfaces of rehabilitated wastewater manholes shall have anapproved coating to protect the rehabilitated manhole interior surface from thehydrogen sulfide gases and the sulfuric acid effects of municipal wastewater.Contractor shall provide all labor and equipment necessary to clean and makeany repairs and any other surface preparation to the existing manhole interiorprior to applying the approved coating.

Prior to the application of the approved coating, the interior surface of themanhole shall be cleaned by either sandblasting or high pressure water blasting,followed by manhole interior surface repair and filling of joints. Repair ofdamaged areas of concrete manhole interiors and filling joints of pre-castsections shall be accomplished with grout as recommended by the approvedcoating manufacturer. Pointing of joints of brick manholes shall beaccomplished with mortar or grout as recommended by the approved coatingmanufacturer. Cure time of materials used for repair of damaged areas andfilling of joints prior to application of the approved final coating shall be asrecommended by the coating manufacturer.

Where manhole rehabilitation is to be performed in conjunction with raising ofcastings, construction shall also include the installation of pre-cast grade ringsand application of the approved coating to the rings.

If the adjustment involves lowering the top of a manhole, a sufficient depth ofpre-cast concrete rings or brick courses shall be removed to permitreconstruction. The mortar shall be cleaned from the top surface remaining inplace and from all brick or concrete rings to be reused and the manhole rebuiltto the required elevation. The manhole ring and cover shall then be installedwith the top surface conforming to the proposed grade.

If the adjustment involves raising the elevation of the top of the manhole inaccordance with 'New Manhole Construction and Minor Manhole Adjustment'section of Special Specification Item entitled "Manholes", the top of brick or

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concrete ring shall be cleaned and built up vertically to the new elevation, usingnew or salvaged concrete rings or bricks and the ring and cover installed withthe top surface conforming to the proposed grade.

Cast-in-place foundations shall have a minimum depth of 12 inches at theinvert flowline. The widths of all manhole inverts shall be specifically sizedfor the connecting pipes. Inverts shall be “U” shaped with a minimum depth ofthree fourths of the largest pipe diameter. The invert shall have a minimum fallof 0.10 of a foot between the inlet and outlet. The lowermost riser section maybe set in the concrete while still green, after which the foundation shall be cureda minimum of 24 hours prior to proceeding with construction of the manhole upto 12 feet in depth. The foundation shall be cured an additional 24 hours priorto continuing construction above the 12 foot level. Manhole depth shall bemeasured from the invert flowline to the finish surface elevation.

If required by method of rehabilitation, Contractor shall provide for the flow ofwastewater around the manhole or sections of pipe designated forrehabilitation, including active services in the rehabilitation section. The bypassshall be made by plugging the line at an existing upstream manhole. The pumpand bypass lines shall be of adequate capacity and size to handle the anticipatedmaximum hourly flow. The Contractor shall take all necessary steps to preventflooding of any private property and shall be liable for damages incurred by theflooding. No sewage shall be allowed to drain into earthen sump pits.

When performed in conjunction with roadway construction, repairs, oroverlays, manholes shall be completed to finish elevation and acceptance testedprior to placement of the roadway's finish surface. Backfill for manholes shallconform to the materials required and the density requirements of SpecialSpecification Item entitled "Pipe". Manhole ring adjustment in roadways maybe staged to facilitate base construction. Manhole rings adjusted to interimelevations shall be covered with steel plates of sufficient thickness to supportvehicular traffic. Contractor shall submit the thickness of the steel plate alongwith calculations indicating that it will handle an H20 Live Load. Steel plateson wastewater manholes shall be set in mortar to minimize inflow. The over-excavation required for the grade ring installation shall be backfilled withcement stabilized sand (2 sacks per cubic yard) up to the bottom of Portlandcement concrete pavement slabs or to within 2 inches of finish elevation ofasphaltic concrete pavements. The cement stabilized sand shall be a minimumof 12 inches thick.

All backfilling and compaction shall be completed prior to the commencementof testing.

S506S.5 Acceptance Testing of Wastewater Manholes:

Manholes shall be tested separately and independently of the wastewater lines.

A. Test by the Vacuum Method:

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A vacuum test shall be performed by the Contractor prior to backfillingthose manholes that fall within the right-of-way that require detouring ofvehicular traffic. A second vacuum test will not be required afterbackfilling and compaction is complete unless there is evidence that themanhole has been damaged or disturbed subsequent to the initial vacuumtest.

For manhole installations which do not require detouring of vehiculartraffic, the vacuum method is recommended and may be used by theContractor prior to backfilling the manhole to insure proper installation sothat defects may be located and repaired; however, a vacuum test shall beperformed after backfilling, and compaction are complete. Testing afterbackfill and compaction are complete will be the basis for acceptance of themanhole.

1. Equipment:

a) Manhole vacuum tester shall be by P.A. Glazier, Inc., CherneIndustries, or other manufacturer acceptable to the Engineer ordesignated representative.

b) Pipe sealing plugs shall have a load resisting capacity equal to orgreater than that required for the size of the connected pipe to besealed.

2. Procedures.

a) Manhole section interiors shall be carefully inspected and unitsfound to have through-wall lift holes, or any penetration of theinterior surface by inserts provided to facilitate handling, will not beaccepted. Coating shall be applied after the testing unless coating isapplied before installation or unless it is applied at the factory. Alllift holes and exterior joints shall be plugged with an acceptablenon-shrink grout. No grout shall be placed in horizontal joints.

b) After cleaning the interior surfaces of the manhole, the Contractorshall place and inflate pneumatic plugs in all of the connecting pipesto isolate the manhole; sealing pressure within the plugs shall be asrecommended by the plug manufacturer. Plugs and the ends ofpipes connected by flexible boots shall be blocked to prevent theirmovement during the vacuum test.

c) The vacuum test head shall be placed on the top of the cone sectionor, inside of the top of the manhole cone section, and thecompression seal band inflated to the pressure recommended by itsmanufacturer. The vacuum pump shall be connected to the outletport with the valve open. When a vacuum of 10 inches of mercury(-5 psig) has been attained, the valve shall be closed and the timenoted. Tampering with the test equipment will not be allowed.

d) The manhole shall have passed the test if the vacuum does not dropbelow 9 inches of mercury (-4.5 psig)] within three (3) minutes of

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the time the valve was closed. The actual vacuum shall be recordedat the end of the three (3) minutes during which the valve wasclosed.

e) When the standard vacuum test cannot be performed because ofdesign or material constraints (examples: T-Type manholes, T-LockLiners, or other reasons acceptable to the E/A), testing of individualjoints shall be performed as directed by the E/A.

B. Test by the Exfiltration Method

At the discretion of the Engineer or designated representative, theContractor may substitute the Exfiltration Method of testing for theVacuum test described in 506.4(1) above. This method may only be usedwhen ground water is not present. If ground water is present a VacuumTest shall be used unless otherwise directed by the Engineer or designatedrepresentative. All backfilling and compaction shall be completed prior tothe commencement of testing.

Testing procedures shall be as follows:1. Manhole section interiors shall be carefully inspected; units found to

have through-wall lift holes, or any penetration of the interior surface byinserts provided to facilitate handling, will not be accepted. Coatingshall be applied after the testing unless coating is applied before fieldassembly, or at the factory. All lift holes and exterior joints shall beplugged with an acceptable non-shrink grout. No grout shall be placedin horizontal joints.

2. After cleaning the interior surface of the manhole, the Contractor shallplace and inflate pneumatic plugs in all of the connecting pipes toisolate the manhole; sealing pressure within the plugs shall be asrecommended by the plug manufacturer.

3. Concrete manholes shall be filled with water or otherwise thoroughlywetted for a period of 24 hours prior to testing.

4. At the start of the test, the manhole shall be filled to the top with water.The test time shall be 1 hour (60 minutes). The Construction Inspectormust be present for observation during the entire time of the test.Permissible loss of water in the 1 hour test time is 0.025 gallons perdiameter foot, per foot of manhole depth. For a 4 foot diametermanhole, this quantity converts to a maximum permissible drop in thewater level (from the top of the manhole cone) of 0.05 inches per foot ofmanhole depth or 0.5 inches for a 10 foot deep manhole.

C. Failure to Pass the Test -- Records of Tests

If the manhole fails to pass the initial test method as described in (1) Testby the Vacuum Method and, if allowed, (2) Test by the Exfiltration Method,or if visible groundwater leakage into the manhole is observed, theContractor shall locate the leak, if necessary by disassembly of themanhole, checking gaskets and replacing if necessary, re-lubrication and re-

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assembly, or Contractor may install an acceptable exterior joint sealingproduct (see City of Austin SPL No. WW-146A) on all joints and thenretested. If any manhole fails the vacuum and/or exfiltration test twice, theContractor shall consider replacing that manhole. If the Contractor choosesto attempt to repair that manhole, the manhole must be retested until itpasses. In no case shall cold applied preformed plastic gaskets be used forrepair. Records of all manhole testing shall be made available to theEngineer or designated representative at the close of each working day, oras otherwise directed. Any damaged or visually defective products, or anyproducts out of acceptable tolerance shall be removed from the site.

At a minimum, test Records shall include the following and shall be part ofthe Project records turned in with the acceptance package.

Name of the manhole manufacturerDate tested/date re-testedPassed/failed and state what was done to correct the problemTest Method UsedLocation/station of manholePrecast/cast-in- place bottomType of CoatingAny repairs made to the joints.

D. Inspection:The Engineer or designated representative shall make a visual inspection ofeach manhole after it has passed the testing requirements and is consideredto be in its final condition. The inspection shall determine the completenessof the manhole; any defects shall be corrected to the satisfaction of theEngineer or designated representative.

S512S.6 Measurement and Payment:

Work performed and materials furnished as prescribed by this item as indicatedshall be measured and paid for by an appropriate bid item in accordance withTxDOT Special Specification Item entitled “Water and Wastewater Utilities”, asidentified in the sections entitled “Measurement" and “Payment".

END

Cross Reference MaterialsSpecial Specification Item No. SS512S, "Manhole Rehabilitation"

Texas Department of Transportation: Standard Specifications forConstruction and Maintenance of Highways, Streets, and BridgesDesignation DescriptionItem 420 Concrete Structures

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Item 421 Portland Cement ConcreteItem 440 Reinforcing SteelSection 421.2(5) Fine AggregateCity of Austin Utilities Criteria ManualDesignation DescriptionSection 2 Water and Wastewater Design Criteria

Cross Reference MaterialsSpecial Specification Item No. SS512S, "Manhole Rehabilitation"

City of Austin Special Specification ItemsDesignation DescriptionSS503S Frames, Grates, Rings and CoversSS504S Adjusting Structures

SS506S ManholesSS507S BulkheadsSS510S Pipe

City of Austin Standard DetailsDesignation Description

21. 100S-1 Casting Adjustments503S-4S Storm Sewer Manhole Ring and 813 mm (32”) Cover503S-4W Sanitary Sewer Manhole Ring and 813 mm (32”)Cover503S-5S Bolted Storm Sewer Manhole Ring and 813 mm(32”) Cover

22. 503S-5W Watertight

23. 506S-1 Manhole Invert Plan

24. 506S-2 Major Manhole Adjustment506S-4 New Manhole Construction and Minor ManholeAdjustment

(1) 506S-5 Typical Box Manhole 750mm (30”) and Larger Pipe

(2) 506S-7 Precast Manhole with DropInlet

(3) 506S-8 Precast Manhole with DropInlet on Precast Base

(4) 506S-9 Precas506S-10 Wastewater Manhole on Precast Base506S-11 Storm Sewer Manhole Details

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(5) 506S-12 O-Ring Joint Detail,Precast Manhole Section506S-13 Wedge Seal Joint Detail, Precast Manhole SectionCity of Austin Water and Wastewater Utility DocumentsDesignation Description

SPL WW-146A Manhole Seals, Plastic, WatertightSPL WW-511 Lining System, Corrosion ResistantAmerican Society for Testing and Materials (ASTM)Designation DescriptionASTM C-62 Specification for Building Brick (Solid Units Made from Clayor Shale)ASTM C-55 Specification for Concrete Building BrickASTM C-478/C-478M Standard Specification for Precast ConcreteManholeASTM C-478/C-478M Specification for Precast Reinforced Concrete ManholeSectionsASTM C-443/C-443M Specification for Joints for Circular Concrete Sewer andCulvert Pipe, Using Rubber GasketsASTM C-923/C-923M Specification for Resilient Connectors BetweenReinforced Concrete Manhole Structures PipesAmerican Association of State Highway and Transportation Officials(AASHTO)Designation DescriptionM-306 Standard Specifications for Drainage StructureCastings

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ITEM NO. 02164

MICROTUNNEL ACCESS SHAFTS AND RETENTION SYSTEM

02164-1: DESCRIPTION

A. Scope of Work

1. The Work under this Section includes furnishing all labor, tools, equipment and materialsto install the tunnel access shafts. Installation activities shall include but not be limited to:design of the shaft retention system; handling, removal and disposal of materials encounteredin the shaft excavation; installation of retention system; groundwater control and disposal;lighting and electrical; safety facilities; and all other appurtenant work.

2. The presentation of minimum requirements herein does not alleviate or diminish the soleresponsibility of the CONTRACTOR for the design and installation of the system and thesafety of his or her workers.

B. Requirements

1. The retention systems defined in this Section are based on the following access shaftdiameters:

LocationMaximum Diameter

or LessJacking Shafts 18 ftRetrieving Shafts 14 ft

Larger diameter shafts, within the limits specified above, may not be used, unless approvedby the Engineer and provided the shaft retention system is designed in accordance withcriteria defined in this Specification and design is submitted in accordance with thesubmittals requirements.

2. Only contractors with proven past experience with access shaft construction excavationand retention system installation in similar subsurface conditions, may perform the work.Contractors and specialty contractors meeting the qualification requirements for shaftconstruction may perform the work described in this Section.

3. The retention system shall be designed in accordance with the criteria given in the“Geotechnical Baseline Conditions for Water and Wastewater Utilities” and sealed by aProfessional Engineer registered in the State of Texas with experience in designing retentionsystems with similar subsurface conditions.

4. The access shaft retention system shall consist of one of the following four systems or asapproved by the Engineer.

a. The access shaft retention system shall consist of steel liner plates, with orwithout horizontal ribs to allow for incremental excavation and subsequentinstallation of plates prior to continuing excavation. The plates shall be

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waterproofed by gasket or caulking. In addition, grouting behind the installedplates is required to prevent water intrusion into the shafts from below thebottom rung of plates. A minimum 12-inch thick concrete seal slab shall beinstalled as a floor of the shafts to maintain a stable working surface.

b. The shaft excavation may be drilled with a pier rig with adequate capacity.Slurry displacement method may be required to maintain the excavation priorto installation of corrugated steel casing or other casing type. Ring beams maybe required to strengthen the casing. The annulus shall be grouted to make thesystem water-tight.

c. A soldier pier system with either wood lagging or precast concrete panels maybe used. The system may require being tied-back or interior ring beams. Thissystem would require grouting and well points to control groundwaterintrusion.

d. Retain the soil/weathered limestone with a system 1 to 3 above and use nails orcladding as described in the Item No. 5501 “Geotechnical Baseline Conditionsfor Water and Wastewater Utilities” for competent limestone.

C. Classification of Excavation

1. There shall be no classification for payment of the various materials encountered intunnel construction, except as otherwise indicated in the Contract Documents.

2. The “Geotechnical Baseline Conditions for Water and Wastewater Utilities” containsgeotechnical data and predictions of geologic conditions to be encountered duringconstruction of the Work.

3. The CONTRACTOR shall use the predicted conditions of the “Geotechnical BaselineConditions for Water and Wastewater” to plan and bid the Work.

4. The ENGINEER will use the “Geotechnical Baseline Conditions for Water andWastewater Utilities” to identify and quantify Differing Site Conditions that may beencountered during the Work.

D. Sequencing

Coordinate activities with other work being performed at the site not to cause anyinterruption during work being completed under this Section.

02164-2: SUBMITTALS

A. At least 30 days prior to the start of microtunneling or shaft construction, theCONTRACTOR shall submit a description of access shaft installation operations to theENGINEER. The submittal shall include descriptions of the proposed site facilities,equipment to be utilized, and methods of construction. The ENGINEER shall review thesedescriptions for compliance with Contract requirements. The descriptions shall include, butnot be limited to:

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1. Design of Shaft Retention system complete with design calculations, assumptions andloadings.

2. PLANS and Specifications for installation of retention sealed by a ProfessionalEngineer registered in the State of Texas.

3. Groundwater control plan for seepage, if it occurs.

4. Method of excavation and spoil disposal.

5. Grout material and procedures for filling the void space outside the liner plates.

6. Equipment and procedures to provide ventilation and control hazardous gas.

7. Equipment and procedures to illuminate the work areas.

8. Safety plan for underground and ground surface operations, showing compliance withapplicable regulations and laws.

9. Daily, during the work, submit a log of spoil removed from the site.

10. Approved disposal site for excess excavated material to be removed from the worksite.

11. The methods proposed shall provide for immediate, continuous, and adequate supportof the ground, adjacent structures, and other facilities.

02164-3: MATERIALS

(NOT USED)

02164-4: EXECUTION

(NOT USED)

02164-5: MEASUREMENT AND PAYMENT METHODS

Work performed and materials furnished as prescribed by this item will not be measured norpaid for directly but shall be considered subsidiary to Contract bid items. Include cost of samein Contract price bid for work of which this is a component part.

END OF SECTION 02164

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ITEM No. 02312

TUNNEL EXCAVATION BY MICROTUNNEL BORING MACHINE

02312- 1: DESCRIPTION

A. Scope of Work:1. The work includes design, procurement, installation, and execution of

Microtunnel excavation by Microtunnel Boring Machine for all sections theContractor plans to use a Microtunnel Boring Machine for the U.S. 183 UtilityRelocation Cameron Road to U.S. 290, Austin Texas.

2. All work specified is the responsibility of the Contractor, subject to the approvalof the Engineer. Perform work in accordance with all current applicable regulationsand codes of Federal, State, and local agencies. In the event of conflict, comply withthe strictest requirements. No part of this specification shall be construed as arelaxation of any of these rules, laws, and regulations.

3. Furnish all labor, materials, and equipment required to excavate the UtilityRelocation Microtunnel, to the minimum dimensions and grades as shown on theDrawings and as required to perform the work by use of a Microtunnel BoringMachine (MTBM).

4. Construction methods shall satisfy the requirements of the section while utilizingand preserving the inherent strength of the rock mass surrounding the microtunnel.The strength of the rock mass forms the foundation of the permanent support for thismicrotunnel.

5. Excavated dimensions and arrangements shown on the Drawings for themicrotunnel are approximate dimensions. Subject to the approval of the Engineer, theContractor may select such dimensions as he may required to conduct the work, basedon space requirements for the equipment used, installation of components, handling ofexcavated rock, methods of construction, and ancillary services.

6. The Contractor shall be responsible for furnishing and installing all electricalequipment required to complete the microtunnel construction activities both on thesurface and underground at the construction sites. The Contractor shall also furnishthe electrical equipment for all of the auxiliary systems which shall include but not belimited to transformers, panel boards, security lighting, grounding, power for ventfans, sump pumps, disconnect switches, voice communication equipment, officetrailers, etc. The work shall include the following:a. Electric lines shall be sized for the loads and rated properly for the delivery

voltage.b. Lighting in the shaft areas, and in the vicinity of all operating equipment.c. The Contractor as required will provide communication equipment.

B. Related Work:

1. Section 02164: Microtunnel Access Shafts and Retention System.

2. Item No. 5501: Geotechnical Baseline Conditions for Water and Wastewater Utilities.

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3. Item No. SS510 : Pipe

C. Definitions:

1. Annular Space – The void created between the outside diameter of pipe being installedand extreme outer limits created by MTBM bore process.

2. Earth Pressure Balance - MTBM pressure applied to the cutting face equals the pressureof the earth against the cutting face.

3. Full Face Control - Complete mechanical support of the excavated face at all times.

4. Lubricant - A substance applied between the pipe and soil to minimize friction and to fillthe annular space.

5. Microtunnel Boring Machine (MTBM) - A remotely controlled, steer able, laser-guidedmicrotunnel boring machine consisting of an articulated boring machine shield and a rotatingcutting head.

6. Pipe String - The succession of joined individual pipes being used to advance theexcavation equipment.

7. Shaft or Pit - A vertical excavation to insert or receive microtunneling equipment andpipe.

8. Slurry- Water mixture, which may contain additives, that is used to transport spoils andcounterbalance any groundwater pressure.

D. Design Criteria:1. Pressurized, close face remotely operated microtunneling equipment shall be used for

all microtunneling work described.2. Microtunneling and associated equipment selected by the Contractor shall be

compatible with the geological conditions described in the Item No. 5501“Geotechnical Baseline Conditions for Water and Wastewater Utilities”.

3. Face pressure exerted at the heading by the microtunneling machine shall bemaintained as required to balance soil and groundwater pressures present, and preventloss of ground, groundwater inflows, and settlement or heave of the ground surface.Control ground surface settlement or heave above the centerline of the pipeline to 1inch or less. The Contractor shall repair any damage resulting from surface settlementor heave caused by microtunneling, or jacking and receiving pit excavation andconstruction at no additional cost the Owner.

4. The thrust block shall be constructed perpendicular to the proposed pipe alignmentand shall be designed to withstand the maximum jacking pressure to be used, with asafety factor of at least 2.5 without excessive deflection or displacement.

5. Dewatering methods for groundwater control shall not be permitted for construction.

E. Quality Assurance and Control:

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1. Microtunnel Project Manager: The Contractor’s MicrotunnelProject Manager must have at least 10 years of experience inmicrotunnel construction with the methods specified.

2. The Contractor’s MTBM Operators shall have a minimum of fiveyears’ experience in microtunnel excavation with the methodsspecified.

3. The Contractor shall provide quality control, testing, andinspection as required herein, and in accordance with approvedsubmittals. The Contractor’s design engineer shall visit the siteto observe the work in progress as necessary to assure the work isconducted in accordance with the design and that designassumptions are accurate based on field conditions.

4. Tolerances to line and grade for the microtunnel constructionshall be as follows:

a. Horizontal Alignment: Maximum departure of 1 inch at any point along the theoreticalmicrotunnel centerline.

b. Vertical Alignment: Maximum departure of 1 inch at any point along the theoreticalmicrotunnel grade line.

c. Water shall be free draining between any two points at the pipe invert. No reversegrades will be allowed.

F. Requirements:

1. The Contractor shall have the sole responsibility for maintenance and protection ofexisting utilities, structures, and facilities within the zone of construction.

2. The Contractor shall have the sole responsibility for sizing the shafts within the limitsspecified. Shafts shall not exceed 18 ft excavated diameter. The size of the excavations shallbe adequate to construct all structures required and to gain access to tunneling operations forall materials, equipment, and personnel.

3. The Contractor shall allow the Engineer and Owner’s representative access to the shafts,and to use the shafts to access microtunnel operations.

G. Safety:1. Method of construction shall be such as to ensure the safety of the work, project

participants, the public, third parties, and adjacent property, whether public or private.All work shall conform to the requirements of all Federal, State, and local laws andregulations. The Contractor is solely and completely responsible for maintaining safework conditions at the site at all times.

2. The safety officer shall administer an accident prevention program, and shallprepare a code of safe practices and an emergency plan. Provide the Engineer with acopy of each prior to starting tunnel excavation. Hold safety meetings and providesafety instruction for new employees.

H. References:

1. Codes: Occupational Safety and Health Administration (OSHA) Regulations and Standardsfor Underground Construction, 29 CFR Part, 1926, Subpart S.

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02312- 2: SUBMITTALS

A. Shop Drawings: Submit the following shop drawings describing the microtunnelingequipment and methods, a minimum of eight weeks prior to mobilization of themicrotunneling equipment:1. A detailed description of the microtunneling equipment and

procedures to be employed. Provide manufacturer’s literature describing in detail themicrotunneling system to be used including machine type, spoil removal system,surveying procedures and provisions for injecting pipe lubricants.

2. Describe machine capabilities and procedures for undergroundexcavation and minimize loss of ground. Provide descriptions of projects on which thissystem has been successfully used including names, addresses and telephone numbersof Owner’s representatives for these projects as well as length, diameter, pipe materialused, project cost and geological conditions encountered.

3. Schedule for microtunneling work identifying all majorconstruction activities as independent items. The schedule shall include mobilization;shaft excavation and excavation support; jacking equipment setup; installation of pipe;site restoration; cleanup; and demobilization. Any action with an anticipated durationlonger than one (1) week shall be listed separately in the task list of the schedule. Theschedule shall be reviewed with the Engineer and be updated and resubmitted by theContractor on a bi-weekly basis.

4. Provide a description of the alignment control and steeringsystems. Provide manufacturer’s literature, drawings showing setup and supportprovisions, and other details for the laser. Submit a description of surveying methods toset laser positions and a description of procedures to check laser and reset or realignlaser during construction. Confirm that these systems can achieve the requiredpipeline line and grade within the specified tolerances.

5. Submit name and resume of surveyor licensed in the State ofTexas who shall be responsible for setting survey control and laser for pipeinstallation.

6. Capacity, number and arrangement of main jacks. Providedetails of thrust ring, jacking controls and pressure gages. Provide an estimate ofmaximum jacking force expected to be required to complete each drive.

7. Provide thrust block and jacking frame design and details.Submit calculations demonstrating that the thrust block can transfer the maximumplanned forces developed by the main jacks to the ground without excessivemovements.

8. Provide details of pipe lubrication injection system and pipelubricants to be used during microtunneling, including manufacturer’s literature.

9. Provide spoil and/or slurry handling, separation, transport, anddisposal equipment and procedures indicating details of the slurry additives, slurryseparation plant, and the location of slurry and spoil disposal sites for microtunneling.

10. Submit written documentation from the approved disposalsite(s) indicating that they will accept the spoil and are in compliance with all City,State, and Federal regulations.

11. Provide a safety plan for the microtunneling operationsincluding provisions for ventilation, and electrical system safeguards. Submit name ofContractor’s site safety representative responsible for implementing safety program.

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12. Provide a general plan, procedures, and details forconstructing recovery shafts and other methods to remove obstructions that may beencountered during microtunneling.

13. Provisions for protecting adjacent facilities and utilities.C Submit to the Engineer the following reports and records:

1. Qualification for MTBM Staff: Submit within 60 days of the Notice toProceed, qualifications and experience of individuals to be involved in tunnelconstruction including the proposed Microtunnel Project Manager, and MTBMOperators that meet the requirements as specified and as required in ”Statement ofMicrotunnel Contractor Experience” .

2. Submit survey measurements of surface settlement points to the Engineer bythe end of the same day that measurements are taken.

3. Submit by the end of shift worked: Survey notes; records and shift reports;and a floppy or compact disc in a format to be imported to Microsoft Excel,indicating thrust force, cutterhead torque, rate of advance, line and gradedeviation, roll, inclination, laser position, steering altitude, slurry face pressureand other pertinent information from the data logger. The Contractor shall at alltimes provide and maintain instrumentation that will accurately provide to theEngineer all required reports and records.

4. During microtunneling, display instruments in the control cabin indicatingthrust force, cutterhead torque, rate of advance, line and grade deviation, roll,inclination, steering adjustments, slurry face pressure and other pertinentinformation shall be accessible for observation and documentation by theEngineer.

02312- 3: MATERIALS

A. Equipment:

1. Micro Tunnel Boring Machine: The MTBM shall be a full-face machine designedand built or rebuilt for the ground conditions on this project by a recognized MTBMmanufacturer with at least 5 years experience in the design and manufacture of MTBMsof this type. All of the various components and systems, which make up the MTBM shallbe new or reconditioned so that the machine is ready to operate upon installation at thesite. It shall be able, with excess capacity, to handle the range of geological conditionsindicated in the Item No. 5501 “Geotechnical Baseline Conditions for Water andWastewater Utilities”, and shall satisfy the following requirements:a. The machine shall be capable of fully supporting the face during both excavation

and shutdown periods, and shall have the capability of exerting a controllable,measurable, continuous, stabilizing pressure at the face as required to prevent lossof ground. The system shall be capable of adjustments required to balance the soilpressures at the tunnel face to an accuracy of one foot of equivalent hydrostaticpressure. The machine shall utilize a synchronized slurry transportation systemwith machine advance rate to avoid over excavation or loss of ground. Themicrotunneling system shall be capable of back flushing to clear debris that may beencountered.

b. Provide a machine with an enclosed chamber for containing the slurry underpressure. A pressure gage should be provided so that operator can monitor the

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chamber pressure. The system shall be capable of making the adjustments requiredto counterbalance the earth pressures as needed to prevent loss of ground.

c. The machine shall be remotely operated, laser guided, and monitored continuouslyby the operator. A display showing the position of the machine in relation to designline-and-grade shall be provided at the operation console to allow the operator tomonitor face pressure, roll, inclination, laser position, steering attitude, slurry facepressure, rate of advance, installed length, thrust force and cutterhead torque. Themachine shall have a data logger that records all the above at a minimum of 10minutes intervals to a floppy disc or compact disc in a format that can be importedinto Microsoft Excel.

d. The machine shall have a laser guidance system with a light sensitive or electronictarget appropriate for the drive lengths required and capable of achieving the line-and-grade control requirements for the project.

e. The machine shall have an articulated shield that is steerable in both vertical andhorizontal directions to maintain line-and-grade within the specified tolerances.The cutterhead shall have a reversible drive system so that it can rotate in eitherdirection to minimize rotation or roll of the pipe during installation.

f. The machine shall be capable of advancing through the geological conditionsdescribed in the Item No. 5501 “Geotechnical Baseline Conditions for Water andWastewater Utilities”.

g. Provide a slurry separation plant that is appropriate for the soils and rocks beingexcavated, and compatible with the anticipated excavation rate, effective inremoving the spoil from the slurry, and is acceptable in terms of the availableconstruction staging areas.

h. The machine shall be equipped for continuous gas monitoring and shall have ashut-off switch.

i. A pipe lubrication injection system shall be provided to inject pipe lubricants asrequired to minimize jacking force.

j. The tail of machine shall have gaskets and seals to prevent material from runninginto the tunnel at the contact between the tail skin and the steel encasement/pipe.

k. The maximum allowable over-cut shall not be greater than ¾ inch larger indiameter than the outside of the jacked steel encasement/pipe.

2. Jacking System:a. The main jacks shall be mounted in a jacking frame and located in the

jacking shaft. The MTBM shall be moved forward by the jacks advancing asuccessive string of connected pipes toward a receiving shaft.

b. A pipe lubrication system shall be used to lower the friction developedon the surface of the pipe during jacking operation. An approved lubricant,typically bentonite or polymers, shall be injected at the rear of the MTBM orthrough lubrication ports.

c. The steel encasement/pipe lubrication system pressure shall becontinuously monitored, recorded, and controlled to prevent pipe buckling and/orground heave.

d. Thrust block shall be perpendicular to the proposed steelencasement/pipe alignment. The thrust block shall be capable of supporting themaximum jacking pressure developed by the main jacking system.

e. Operate the jacks so not to exceed 80 percent of their rated capacity.Provide additional jacking capacity, such as intermediate jacking stations, if the

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jacking requirements shall otherwise exceed 80 percent. The maximum jackingload shall not exceed 50 percent of the axial load capacity of the steel encasement/pipe.

f. When intermediate jacking stations are utilized, the maximum jackingforce shall not exceed the maximum allowable jacking load of the steelencasement/pipe.

3. Automated Spoils Transportation: The MTBM shall include one of the following:a. Slurry System: The system shall be capable of measuring earth and

groundwater pressure and making the adjustments required to counter-balance theearth and groundwater pressure to prevent loss of slurry or uncontrolled soil andgroundwater inflow and shall satisfy the following requirements: i. The slurry pressure at the excavation face shall be controlled by use of slurry

pumps. ii. A slurry bypass method shall be included to allow for a change in direction of

flow to be made and /or isolated. iii. Provide a separation process, properly sized for the tunnel being constructed,

the soil type being excavated, and the workspace available at each area.Separate the spoil from the slurry so that slurry shall be returned to the cuttingface for reuse.

iv. Monitor the composition of the slurry to maintain the slurry density andviscosity limits as approved in the submittals.

b. Mechanical Earth Pressure Balance System: The system shall monitor andcontinuously balance the soil and groundwater pressure. The system shall becapable of adjustments required to maintain face stability for the particular soilcondition to be encountered to prevent soil loss or uncontrolled groundwater inflow. i. Maintain the pressure at the excavation face by controlling the volume of spoil

removal with respect to the advance rate. Monitor the speed of rotation of thescrew conveyor and the amount of water added.

ii. Provide an evaluation of equipment’s ability to balance earth and water pressureat the face, stability of the soils, and the significance of the groundwater presentfor the Engineer’s review.

4. Grout: Grout to fill voids between the pipe and the ground shall consist of Portlandcement, water, and fly ash as required to produce a satisfactory pump-able grout with aminimum 28-day compressive strength of at least 500 psi.

02312- 4: CONSTRUCTION METHODS

A. General1. Prior to commencement of MTBM excavation, the Contractor shall furnish all

labor, materials, and equipment to excavate and support a shaft in accordance withspecification Section 02164 “Microtunnel Access Shafts and Retention System”,as necessary, to initiate MTBM operations.

2. The Contractor shall determine the size, length and appropriate support systemfor any required starter tunnel.

3. Perform microtunnel excavation as shown on the Contract Drawings and asspecified in this section.

4. The 24-inch sewer shall be installed using microtunneling methods between thelimits indicated on the plans to the specified line-and-grade and utilizing methods,

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which include due regard for safety of workers, adjacent structures andimprovements, utilities, and the public. Jacking and receiving pits shall be locatedas identified on the plans, unless approved otherwise by the Engineer.

5. A thrust block is required to transfer jacking loads to the soil behind the jackingpit. The thrust block shall be properly designed and constructed and shall beperpendicular to the proposed steel encasement/pipe alignment. The thrust blockshall be designed to support the maximum obtainable jacking pressure developedby the main jacks or the microtunneling machine.

6. Provide launching seals to prevent loss of ground and loss of lubricants at jackingpits.

7. No gasoline powered equipment shall be permitted in jacking and receiving pits.Diesel, electrical, hydraulic, and air powered equipment is acceptable, subject toapplicable City, State, and Federal regulations.

8. Conduct all operations such that trucks and other construction vehicles do notcreate a dust nuisance in the streets and adjacent properties. Promptly clean up,remove and properly dispose of any spoil or slurry spillage.

9. All work shall be done so as not to disturb roadways, adjacent structures,landscaped areas, or utilities. Any damage shall be immediately repaired to thesatisfaction of the property owner, residents, agency or utility having jurisdiction,and the Engineer at no additional cost to the Owner.

10. The Contractor shall construct recovery shafts, in accordance with approvedsubmittals, if obstructions are encountered which stop the microtunneling machinefrom advancing. The shafts shall be properly supported with suitable shoringprovisions to minimize loss of ground and ground movements, which coulddamage adjacent utilities, streets, or structures. Obtain necessary approvals fromaffected agencies and proceed with the construction of recovery shafts as requiredto remove obstructions and minimize delays in the work.

B. Steel Encasement / Pipe Installation1. Steel encasement/pipe installation shall be completed in accordance with

approved shop drawings and accepted submittals.2. Provide a suitable jacking frame and thrust block to carry out the work. Provide

intermediate jacking stations if required to complete the required drives.Intermediate jacking stations shall be provided when the total anticipated jackingforce needed to complete the drive shall exceed the capacity of the main jacks orthe maximum allowable jacking force on the steel encasement/pipe.

3. Special care shall be taken when setting the steel encasement/pipe guide railsprior to starting the work in the jacking pit to ensure correctness of the alignment,grade, and stability. Survey the location and orientation of the guide rails toensure they are on the proper line-and-grade and verify that they are properlysupported.

4. Jacking steel encasement/pipe sections shall be handled and transported from thestorage area to the jacking pit properly in accordance with the manufacturer’srecommendations to avoid damage. Set the jacking steel encasement/pipe sectionsproperly, braced and supported by guide rails. Join the two sections togetherfollowing the below joint connection procedures or as indicated in approvedsubmittals.

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a. Clean both ends of each steel encasement/pipe section and the joint components.

b. Apply joint lubricant to the bell interior surface and gaskets. Use only lubricantsapproved by the encasement/pipe manufacturer.

c. Use suitable equipment and end protection to push the encasements/pipes together.

d. Do not exceed forces recommended by the manufacturer for jointing or pushingencasement/pipe.

5. The axial forces from the thrust jacks shall be distributed to the encasement/pipeuniformly through a properly designed thrust ring and cushion materials, asrecommended by the encasement/pipe manufacturer, to prevent damage to the ends of theencasement/pipe. Jacking forces shall be applied uniformly to the encasement/pipe wall.The jacking system shall be capable of continuously monitoring the jacking pressure andadvance rate.

6. Pipes shall be jacked into position following the design line-and-grade of the pipelinewithout damaging the pipe. In the event a section of the pipe is damaged during thejacking operation, the encasement/pipe shall be jacked through to the receiving pit andremoved. Other methods of repairing the damaged encasement/pipe may be used, subjectto the approval by the Engineer.

7. Provide a lubrication system, and inject lubricants through injection ports in the jackingencasement/pipe as necessary, to minimize friction. Lubricants shall be injectedcontinuously as the pipe is advanced. The volume injected shall not be less than thatrequired to fill the annular void space outside the pipe.

8. Pressure applied at the tunnel face during microtunneling shall be maintained at all timesbetween the measured active earth pressure and 50 percent of the estimated earthpressure. Pressure applied at the tunnel face to balance the groundwater shall bemaintained at a level slightly in excess of normal hydrostatic pressure and shall bemonitored continuously.

9. The microtunneling machine shall be operated so as to minimize both surface heave andloss of ground during microtunneling. Restrict the excavation of the materials to onlythose materials that are physically displaced by the shield itself in order to prevent loss ofground and settlement or possible damage to overlaying structures. Control the advancerate and monitor the volume of material excavated and adjusted advance rate, as requiredto avoid loss of ground, over excavation and surface heave.

10. The microtunneling machine shall be steered to maintain line-and-grade within thetolerance specified. This shall be achieved by continuously monitoring line-and-grade,machine inclination, roll, and steering attitude during the operation. As a minimum, thethrust force, slurry chamber pressure, torque, rate of advance, distance along the drive,deviation from line-and-grade, roll, and steering altitudes shall be monitored andrecorded for each pipe section installed.

C. Spoil Transport and Disposal

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1. Use slurry spoil transportation system for all microtunneling. Monitor slurrypressure and adjust as required to adequately balance earth pressures.

2. A separation plant shall be provided for microtunneling operations to remove theexcavated soil from the slurry for disposal. Use settlement tanks, shakers,vibrating screens, hydro-cyclones and centrifuges as required for effective spoilremoval.

3. Properly transport and dispose of all excavated materials away from theconstruction sites in accordance with all applicable City and State regulations.Slurry from microtunneling operations shall be pumped into tanker trucks andproperly disposed of at acceptable facilities in accordance with current City andState regulations for disposal of these materials.

D. Control of Line-and-Grade

1. The benchmarks and other primary survey control have been established and areshown on the Plans. The Contractor shall verify the accuracy of these benchmarks at thebeginning of construction and report any errors or discrepancies to the Engineer.

2. When satisfied that all benchmarks are correct, use these benchmarks to furnishand maintain all reference lines-and-grades for microtunneling. For microtunneling, usethese lines-and-grades to establish the location of the pipe using laser guidance system.Surveying shall be performed by a surveyor licensed in the State of Texas. Submit to theEngineer copies of the field notes used to established all the lines-and-grades and allowthe Engineer to review laser setup prior to beginning microtunneling. The Contractorshall be fully responsible for the accuracy of the work and the correction of defectivework, as required.

3. Laser shall be mounted independently from the thrust block and jacking frame tomaintain the alignment of the laser. Stop microtunneling operations and reset laser, iflaser alignment shifts or is moved off of design alignment and grade for any reason.Laser shall only be reset by qualified surveying personal in accordance with approvedprocedures.

4. Monitor line-and-grade continuously during microtunneling operations. Recorddeviation with respect to design line-and-grade at least once per foot and submit recordsto the Engineer as requested. Control line-and-grade of the pipe to within the specifiedtolerances.

5. If the pipe installation exceeds the specified tolerances for deviations, correct theinstallation, including, if necessary, redesign of the sewer or structures. All correctivework shall be performed as approved by the Engineer, at no additional cost to the Owner.

E. Emergency Measures

1. Whenever there is a condition that is likely to endanger the stability of theexcavation or adjacent structures, the Contractor shall operate with a full crew for 24hours a day, including weekends and holidays, without intermission until thoseconditions no longer jeopardize the stability of the Work. Emergency operations that can

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not be traced to unforeseen ground conditions shall be conducted at no additional cost tothe Owner.

F. Surface Settlement Monitoring

1. Install and monitor surface settlement points as approved by the Engineer.

2. Measurements shall be taken daily while microtunneling operations are taking place andwithin 100 feet of the settlement points, and at least once per week thereafter untilcompletion of all the work.

02312- 5: MEASUREMENT AND PAYMENT METHOD

Work performed and materials furnished as prescribed by this item as indicated will bemeasured and paid by appropriate bid items in accordance with TxDOT SpecialSpecification “Water and Wastewater Utilities , Sections entitled “Measurement” and“Payment”.

END OF SECTION 02312

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ITEM NO. 02314

INSTALLATION OF CARRIER PIPE

02314-1: DESCRIPTION

A. Scope of Work:

1. The Work under this Section includes furnishing all labor, tools, equipment and materialsto install a primary tunnel liner as required in Specifications for the two-pass installationof the carrier pipe. Microtunneling activities shall include, but not be limited to:excavation; handling, removal and disposal of materials encountered in the microtunnel;installation of initial support; groundwater control and disposal; ventilation, lighting andelectrical; safety facilities; and all other appurtenant work.

2. Determine the excavated size of the tunnel based on microtunneling methods, thespecified line and grade tolerances, requirements for installing pipeline or other liningsand other limitations.

3. Anticipated ground conditions are as described in Item No. 5501, “Geotechnical BaselineConditions for Water and Wastewater Utilities ”.

B. Related Requirements:

Only contractors and specialty contractors who have met the qualifications requirementsof “Statement of Microtunnel Contractor’s Experience” for tunnel construction mayperform the work described in this Section.

C. References:

The publications listed below form a part of this Specificationto the extent referenced. The publications are referred to in the text by basicdesignation only.

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATIONOFFICIALS (AASHTO)

AASHTO M36/M36M Standard Specification for Corrugated Steel Pipe, Metallic-Coatedfor Sewers and Drains

AASHTO Section 16 Thickness Tolerances

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A760/A760M Standard Specification for Corrugated Steel Pipe, Metallic-Coated forSewers and Drains

AMERICAN WATER WORKS ASSOCIATION (AWWA)

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AWWA C200 Steel Water Pipe – 6-Inch (150 mm) and Larger

AWWA C203 Coal-Tar Protective Coatings and Linings for Steel Water Pipelines –Enamel and Tape-Hot Applied

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

29 CFR Part 1926 Subpart S - OSHA Regulations and Standards for UndergroundConstruction

D. Classification of Excavation:

1. There shall be no classification for payment of the various materials encountered inshaft or microtunnel construction, except as otherwise indicated in the ContractDocuments.

2. The “Geotechnical Baseline Conditions for Water and Wastewater Utilities” containsgeotechnical data and predictions of geologic conditions and ground behavior duringthe construction of the Work.

3. The CONTRACTOR shall use the predicted conditions of the “Geotechnical BaselineConditions for Water and Wastewater Utilities” to plan and bid the Work.

4. The ENGINEER will use the “Geotechnical Baseline Conditions for Water andWastewater Utilities” to identify and quantify Differing Site Conditions that may beencountered during the Work.

E. Personnel:

1. During the microtunneling construction portions of the work for which they werequalified, the CONTRACTOR project manager shall be assigned to the job and shall beon-site at least three (3) days per week while work is in progress, and theCONTRACTOR field superintendent shall be present full-time at the job site wheneverwork is in progress.

2. The operator(s) of the microtunneling equipment shall have technical training in theoperation of the proposed equipment and shall have completed at least one tunnel projectwith similar equipment in the least five years.

F. Equipment:

The type of microtunnel equipment to be used shall be similar to that for which theCONTRACTOR has qualified under the requirements of “Statement of MicrotunnelContractor Experience”.

G. Sequencing:

Coordinate tunneling activities with other work being performed so as not to cause anyinterruption in construction operations under this or other Contracts.

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02314-2: SUBMITTALS

A. At least 30 days prior to the start of tunnel construction, the CONTRACTOR shall submit adescription of its microtunneling operations to the ENGINEER. The submittal shall includedescriptions of the proposed site facilities, equipment to be utilized, and methods ofconstruction. The ENGINEER shall review these descriptions for compliance with Contractrequirements. The descriptions shall include, but not be limited to:1. Manufacturers’ specifications and data sheets for microtunneling equipment.2. A schedule showing, at minimum, mobilization, groundwater control, shaft excavation

and support, tunnel drives, contact grouting, placement of carrier pipe, site restoration,cleanup and demobilization.

3. Qualifications of key personnel as required by these Specifications.4. Layout plans and description of operational sequence.5. Methods of excavation, muck removal, and muck disposal.6. Plan for dewatering and treatment of disposed water.7. Grout mixes, injection procedures and monitoring of blowouts.8. Monitoring for surface movements.9. Procedure for placement of the carrier pipe.10. Grout material and procedures for filling annular space between initial support and the

carrier pipe.11. Provisions to prevent flotation of pipe and/or manholes.12. Equipment and procedures to stabilize the microtunnel face and prevent groundwater

inflows.13. Equipment and procedures to provide ventilation and control hazardous gas.14. Equipment and procedures to illuminate the work areas.15. Safety plan for underground and surface operations, showing compliance with applicable

regulations and laws.16. Copies of field notes used to establish all lines and grades.17. Daily, during the work, submit a written log of operations.18. Daily, during the work, submit a log of spoil and muck removed from the site.19. Approved disposal site for excess excavated material to be removed from the work site.

B. The methods proposed shall provide for immediate, continuous and adequate support of theground, adjacent structures and other facilities.

C. The CONTRACTOR shall be responsible for the design of the initial support. Designsubmittals, sealed and signed by a Professional Engineer registered in the State of Texas, willbe required for this design. Submit shop drawings and information showing initial supportsystems for microtunnel construction that conforms to design requirements indicated andspecified in the Contract Documents. Show detailed method of construction; detailedinstallation procedures; method of expansion, shim, connection, or mechanical connection,gasket, compression packing, non-shrink grout, and necessary design calculations.

D. Submit a design mix for the grout proposed to fill the annulus between the initial support andthe carrier pipe.

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E. The ENGINEER’s review of the submitted material shall, in no way, relieve theCONTRACTOR of the responsibility for making a satisfactory installation meeting therequirements of these Documents.

02314-3: MATERIALS

A. Carrier Pipe

The carrier pipe installed in the initial support shall conform to “Centrifugally Cast FiberglassReinforced Polymer Mortar Pipe and Fittings for Microtunnel Construction” (Hobas or equal).

B. Carrier Pipe Spacers

Encasement spacers shall be as manufactured by PSI, Houston, TX; Cascade WaterworksManufacturing, Yorkville, IL; or approved equal.

C. Delivery, Storage and Handling

Handle, ship and store material in a manner that will prevent distortion or other damage. Storethe material in a clean, properly drained location out of contact with the ground. Replace alldamaged material with new material or repair the damaged material in a manner approved by theENGINEER.

02314-4: EXECUTION

A. General

OWNER shall establish survey controls for construction. CONTRACTOR shall check thesecontrols and report any errors or discrepancies to ENGINEER prior to the start of the work.CONTRACTOR shall use these controls to furnish and maintain all grades. CONTRACTORshall submit to ENGINEER copies of field notes used to establish line and grade.

B. Methods

1. CONTRACTOR shall select method or methods most appropriate for excavation ofmicrotunnel and installation of initial support of the tunnel, subject to any restrictions orconstraints set forth in the Contract Documents. CONTRACTOR shall be fully responsiblefor the success of construction methods in complying with all requirements of the PLANSand Specifications.

2. The methods and equipment shall be such that loss of ground from outside the peripheryof the initial support is positively prevented. Stability of the working face shall bemaintained at all times. Ground shall be positively prevented from running or flowing intothe tunnel, through any element of the initial support, or through joints between suchelements, except for material excavated from the face during normal operation.

3. Where necessary to control ground during removal of obstructions or to cope with otherconditions, CONTRACTOR shall within 24 hours apply other measures of ground control.

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4. No gasoline-powered equipment shall be permitted in the tunneling operations. Diesel,electrical, or air-powered equipment will be acceptable, subject to applicable Federal andState regulations. Any diesel engines used shall be equipped with scrubbers.

C. Groundwater Control

1. The CONTRACTOR is responsible for maintaining a dewatered condition duringmicrotunnel construction. The design of the dewatering system shall consider the potentialfor damage to adjacent facilities due to settlement by lowering of the groundwater table.CONTRACTOR shall submit the proposed dewatering plan(s) prior to construction.

2. All groundwater seepage and other water removed from the work site shall be filtered /treated as approved by the OWNER prior to discharge. Discharge method and location shallbe approved by the OWNER. Dewatering system shall be designed and constructed so as toprevent washing of native or in situ materials. Dispose of groundwater in accordance with allapplicable local, State and Federal regulations. CONTRACTOR shall note the expectedcomponents of the sediment in the muck and water, as indicated in the “GeotechnicalBaseline Conditions for Water and Wastewater Utilities”. The OWNER has strictrequirements for treatment/filtration of this water prior to disposal.

D. Ground Movement

1. The CONTRACTOR shall be responsible for monitoring ground movement associatedwith the work and making suitable changes in construction methods to control groundmovements and prevent damage to the Work and adjacent structures. Ground movementshall be limited to less than 0.10 foot at a distance 3.0 feet above the crown of the tunnelduring construction, unless otherwise approved by the ENGINEER. Areas wheremovements exceed these requirements shall be repaired to the satisfaction of the owningagency and as directed by the ENGINEER.

2. Perform microtunnel excavation in a manner that will minimize the movement of theground in front of, above, and surrounding the microtunneling excavation, and minimizesubsidence of the surface above and in the vicinity of the excavation. Support the ground ina manner to prevent loss of ground and keep the perimeter and face of the tunnel stable at alltimes, including shutdown periods. CONTRACTOR shall, at his expense, repair any damagecaused by ground movement.

E. Emergency Measures

Whenever there is a condition that is likely to endanger the stability of the excavation or adjacentstructures, the CONTRACTOR shall operate with a full crew for 24 hours a day, includingweekends and holidays, without intermission, until those conditions no longer jeopardize thestability of the Work.

F. Ventilation

Provide, operate and maintain for the duration of microtunnel operations, a temporary ventilationsystem that supplies fresh air as necessary for personnel entry, and meet all Federal, State andlocal laws, regulations and guidelines, including OSHA and MSHA. Remove system from thesite when work is complete.

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G. Face Control

1. Upon shut-down of tunnel excavation for more than 2 hour, or immediately if siteconditions warrant, the CONTRACTOR shall provide complete face control. Face controlshall be defined as positive measures to prevent movement or loss of soil or water at theexcavated face.

2. If face control is not maintained and caving occurs or voids are created, theCONTRACTOR shall stabilize the ground and fill any holes or voids created prior tocontinuing normal tunnel excavation. The CONTRACTOR shall have on hand at all times,equipment, labor and materials necessary to immediately address and stabilize theseoccurrences.

H. Enlargements

Enlargements of the tunnel opening for the CONTRACTOR’s convenience may be performedwhen approved in writing by the ENGINEER prior to the start of excavation. Provide shopdrawings completely describing the proposed work, including dimensions of the enlargement,excavation, support and concrete backfilling methods.

I. Safety Requirements

1. Methods of construction for microtunneling shall be such as to ensure the safety of thework, project participants, the public, third parties, and adjacent property, whether public orprivate. As a minimum, all work shall conform to the requirements of OSHA. TheCONTRACTOR is solely and completely responsible for maintaining safe-workingconditions at the site at all times.

2. Provide lighting and ventilation to ensure proper performance and inspection of work.3. Control noise and dust in accordance with applicable Federal, State and local laws, safety

codes, regulations and ordinances.4. Maintain clean working conditions within the tunnel at all times. All slurry, slush, grout

spills, ponded water, and other material not required for microtunneling shall be removedfrom the tunnel in a timely manner.

J. Carrier Pipe Installation

1. Install the carrier pipe in such a way as to provide full and complete support of carrierpipe, to prevent flotation until completion of the annulus grouting operation, and to achievefinal alignment and grade of carrier pipe as required on the PLANS.

2. Grout the annulus between the encasement pipe and the carrier pipe with a procedure thatensures complete filling of the annulus, the carrier pipe is undamaged by grouting, and thecarrier pipe is on design line and grade.

K. Electrical System

Temporary power systems and electrical equipment installation shall be in conformance withapplicable portions of the National Electric Code (NEC) and all OSHA requirements. Allsystem and equipment shall be suitable for installation in wet locations. All metallic parts

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shall be properly grounded. Power circuits shall be separate from lighting and ventilatingcircuits. The construction site shall have standby generators of sufficient capacity to operateat least the lighting and ventilating systems. The standby generators shall be operated at notless than weekly intervals to ensure their performance and reliability. The standby powershall automatically and immediately provide power to the lighting and ventilating system. Inlieu of standby generators for lights, the CONTRACTOR may use emergency battery lights inthe tunnel.

L. Lighting

All work areas, including all shafts and microtunnel sections under construction, shall be lightedwith a sufficient number of electric lights to ensure proper safety, work and inspection, and shallcomply with all OSHA requirements. Lighting of the surface work areas during “after dark”operations (when allowed by the OWNER) is also required. All lighting shall be thoroughlyinsulated and shall be kept separate from power circuits.

M. Communications

A three-way voice communications system and an independent electric bell or buzzer systembetween the shaft bottom, and the ground surface shall be installed and kept in operation at alltimes.

02314-5: MEASUREMENT AND PAYMENT

Work Performed and materials furnished as prescribed by thisitem will not be measured nor paid for directly but shall be considered subsidiary toContract bid items. Include cost of same in Contract price bid for work of which this is acomponent part.

END OF SECTION

155-169 591509-02

ITEM NO. 03310

LOW DENSITY CELLULAR CONCRETE FOR MICROTUNNEL BACKFILL

03310-1: DESCRIPTION

A. Scope of Work

1. Section includes: Backfilling the annular space between the final microtunnel liner and theinitial support and/or excavated microtunnel surface.

2. Related Sections:a. Section 02312, “Tunnel Excavation by Microtunnel Boring Machine”.b. Section 02314, “Installation of Carrier Pipe”.

B. References

The publications listed below form a part of this Specification to the extent referenced.The publications are referred to in the text by basic designation only.

AMERICAN CONCRETE INSTITUTE (ACI)

ACI 214: Recommended Practices for Evaluation of Strength Test Results of Concrete

ACI 523.1R-92: Guide for Cast-in-Place Low-Density Concrete

ACI523.3R-93: Guide for CellularConcretes Above 50 pcf, and for Aggregate Concretes Above 50pcf with Compressive Strengths Less Than 2,500 psi

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI B40.1-85 Gauge - Pressure, Indicating Dial Type - Elastic Element

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM C33 Standard Specification for Concrete Aggregates

ASTM C94 Standard Specification for Ready-Mixed Concrete

ASTM C150 Standard Specification for Portland Cement

ASTM C311 Standard Test Methods for Sampling and Testing Fly Ash or NaturalPozzolans for Use as a Mineral Admixture in Portland Cement Concrete

ASTM C494 Specification for Chemical Admixtures for Concrete

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ASTM C495 Standard Test Method for Compressive Strength of Lightweight InsulatingConcrete

ASTM C567 Standard Test Method for Unit Weight of Structural Lightweight Concrete

ASTM C618 Standard Specification for Fly Ash and Raw or Calcined Natural Pozzolanfor Use as a Mineral Admixture in Portland Cement Concrete

ASTM C796 Standard Test Method for Foaming Agents for Use in Producing CellularConcrete Using Preformed Foam

C. Definitions

Low Density Cellular Concrete: A lightweight cementitious material that contains stable airor gas cells uniformly distributed throughout the mixture at a volume percentage greater thantwenty (20) percent.

D. System

1. Performance Requirements: Provide exterior supports and stulling to prevent flotationand distortion of the final microtunnel liner (carrier pipe). Use method(s) that completelyand uniformly fill the annular space between the initial support or excavated ground and theoutside surface of the final microtunnel liner. Provide gauges, monitoring devices, and teststo determine the effectiveness of the grouting operation.

2. Cellular Concrete Unconfined Compressive Strength: At least 300 psi at 28 days. If flyash is used in the mix, strength shall be tested at 56 days.

3. Initial set time.

4. Minimum dry unit weight and minimum wet unit weight.

5. Cement content and water/cement ratio.

6. Sulfate resistance.

7. Admixtures.

E. Quality Assurance

1. Qualificationsa. Company or consultant specializing in the supply and placement of cellular

concrete tunnel backfill shall be capable of developing a mix design, batching, mixing,handling and placing cellular concrete in underground conditions, and shall havefurnished cellular concrete on at least three (3) tunnels of similar type and size. Ifused, a consultant must have the authority to direct the work and shall be on-site full-time during the placement of cellular concrete backfill.

b. Superintendent or foreman responsible for mixing and placing cellularconcrete tunnel backfill shall have experience in similar tunnel conditions or slip-lining operations.

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c. Exterior supports and stulling to prevent flotation and limit deformation of thecarrier pipe shall be as required by specifications. Additional supports shall beprovided if required by the grouting contractor. The supports shall be designed by alicensed Civil Engineer, registered in the State of Texas, experienced in the design ofsuch systems.

d. Compression testing of cylinders shall be done by an ACI certified testinglaboratory.

2. Certifications: Gauges shall conform to an accuracy of no more than one-half (0.5)percent error over the full range of the gauge. The range of the gauge shall not be more than100 percent greater than the design injection pressure.

3. Manufacturer’s Field Representative: The foaming agent material manufacturer shallprovide engineering field services to review the project and the material application prior toany preparation; to approve the materials, equipment and procedures to be used; and toapprove the setup before production of cellular concrete.

4. Pre-Placement Meeting: Within 48 hours prior to the commencement of cellular concretebackfill operations, schedule a meeting with the OWNER and ENGINEER to review alldetails of the backfill concrete mix proportions, placement procedures and sequence,blocking and stulling of the tunnel lining, and testing/inspection requirements.

F. Delivery, Storage and Handling

All manufactured products shall be delivered, stored and handled per manufacturers’instructions.

G. Project Conditions

Microtunnel conditions, including groundwater inflows, are described in the Item No. 5501“Geotechnical Baseline Conditions for Water and Wastewater Utilities”.

H. Sequencing and Scheduling

Blocking, stulling and cellular concrete backfill operations shall be coordinated with installationof the final tunnel lining (carrier pipe).

03310-2: SUBMITTALS

1. Product Data: Provide manufacturer’s information, including specifications, handlingand storage recommendations, and Material Safety Data Sheets for the following:

a. Portland Cement: Source, brand and type.b. Foaming Agent: Brand and content.c. Water: Source and temperature.d. Fly Ash: Source, brand and type.

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e. Fine Aggregate: Source, brand, type and sieve test results.f. Admixtures: Brand, content, batching methods, time of introduction, and

documentation that shows admixtures have a history of demonstrable satisfactoryperformance under equivalent conditions and are compatible with all materials in themix and carrier pipe materials.

2. Working Drawings

a. Proposed sequencing, methods, and equipment for mixing, conveying and placinggrout. Include information on the batch plant, foam generating system, measures forflow control, valve arrangement at point injection, locations of monitoring gauges, andspacing of injection ports.

b. Provide drawings and design calculations for exterior supports and stulling necessaryto maintain the carrier pipe in the required positions and alignment during placementof cellular concrete backfill, including methods to maintain and prevent flotation anddeformation of the pipe and pipe ends. Deformation of the carrier pipe shall be limitedas required by carrier pipe manufacturer.

c. Provide lift drawings showing the following: i. Location, extent and volume of placement(s), and sequence of microtunnel liner

installation and backfill operation.

ii. End bulkhead details.

iii. Location and sizes of embedded items, including vents, slick lines, pipe sleeves,conduits, inserts and bulkheads.

iv. Details for protection of fresh cellular concrete microtunnel backfill from waterinflows and/or zones of water seepage.

3. Quality Assurance/Control

a. Mix Design: Provide a mix design by weight of all ingredients. Include air content asdetermined by ASTM C 796 and wet and dry design densities, as determined by ASTMC567. Include results of at least 10 cylinder compression tests, as determined byASTM C495.

b. Certified cement mill test reports.c. Name and qualifications of independent testing laboratory.d. Quality Control Plan to produce low density cellular concrete, including verification of

mix ingredient quality, sampling, storage and testing.e. Calibration certificates for gauges.f. Qualification Statements for company or consultant responsible for supply and

placement of cellular concrete tunnel backfill.g. Pour Reports: Provide a formatted report summarizing relevant placement and testing

data.

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03310-3: MATERIALS

A. Manufacturers

Foaming Agent: Acceptable products are Mearl Geofoam Liquid Concentrate manufactured byThe Mearl Corporation, Roselle Park, NJ; Rheocell 15 manufactured by Master Builders Inc.,Cleveland, OH; WF 304 Foam Concentrate manufactured by Cellufoam Concrete Systems,Scarborough, Ontario; or equal.

B. Materials

1. Portland Cement: Conform to ASTM C150, Type II, low alkali.

2. Foaming Agent: Conform to manufacturer’s requirements, as tested by ASTM C796.

3. Water (pH not less than 6.7): Must not contain impurities, suspended particles, algae ordissolved natural salts in quantities that will cause corrosion of reinforcing steel or volumechange that will increase shrinkage cracking.

4. Fly Ash: Conform to ASTM C618, Class F.

5. Fine Aggregate: Conform to ASTM C33.

6. Admixtures: Conform to ASTM C494.

C. Equipment

1. General

a. Use equipment for mixing and injecting cellular concrete which is designed forunderground backfill grouting service. Maintain equipment in good operatingcondition, capable of satisfactorily mixing, agitating and forcing cellular concretebackfill into injection ports at a uniform flow rate under the required constantpressure.

b. Backfill grouting equipment shall be configured so flushing can be accomplished withgrout intake valves closed, with water supply valve open, and with grout pump runningat full speed.

c. An adequate inventory of spare parts or backup equipment shall be provided to ensurethat operable backfill grouting equipment is available at all times during the work.Maintain sufficient quantities of spare pressure gauges, stop valves, and other wearparts on site.

2. Batching, Mixing and Pumping Equipment

a. Batching, mixing and pumping equipment shall be compatible and of sufficient sizeand capacity to place cellular concrete to distances and volumes proposed by theCONTRACTOR.

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b. Provide graphical or digital printout record of batch scale readings, accurate to one (1)pound, of the dry mix ingredients before delivery to mixer.

c. Provide a cellular concrete mixer capable of providing a homogenized mix. Mixershall have a water meter, accurate to one-tenth of a cubic foot, for measuring amountof mixing water added to dry mix ingredients. Batch mixing or continuous mixingfoam generating systems may be used, subject to the following requirements.

i. Batch Mixing System: Cement shall be super wetted using high shear/highenergy mixing blades. Mixer drum size shall be four (4) cubic yards or larger.Foam generating equipment shall be calibrated to produce high-grade uniformfoam.

ii. Continuous Mixing System: Equipment shall be equipped with digital readout forRPMs on proportional equipment. Cement shall be super wetted using a highshear/high energy colloidal pump. Colloidal remixer shall be four (4) cubic yardsor larger.

d. A foam generator shall be used to produce a predetermined quantity of preformedfoam which shall be injected into the mixer and blended with the cement slurry. Thefoam generator shall be timer-controlled to repetitively discharge a preselected quantityor to discharge continuously at a fixed rate. Foam generating equipment shall betested and calibrated for dilution percentage, density and volume output.

e. Provide a mechanical agitator to serve as a holding tank between the mixer and thepump to allow continuous pumping.

f. Specially designed batch mixers may be used in conjunction with surge hopperequipped pumps. The rates of mixing and pumping shall be properly adjusted and acontinuous flow of cellular concrete shall be obtained at the point of placement.

g. Provide pumping equipment to handle the volume of cellular concrete to by conveyedwithout segregation. Operate all pumping so that a continuous stream of cellularconcrete, without air pockets, is conveyed. Equip pump with measures to preventsudden excessive grout pressure from developing. Piston pumps shall be used forpumping of cellular concrete.

3. Injection Hoses and Connections

a. Use hose of proper type and diameter to withstand maximum injectionpressures used.

b. At the point of injection, suitable valves and calibrated pressure gauges shall beprovided so that the pressure and grout flow at the grout hole may be regulated andmonitored. A meter shall be provided to measure the total volume of grout pumpedinto each hole. Provide, at or very near the point of injection, a system of valves in theline transporting the grout that will allow easy access for collection of test specimens.Provide an automatic bypass valve set to the maximum pressure specified.

c. Injecting connections shall be a minimum of 2 inches in diameter.d. Provide suitable stop valves at collar of hole for use in maintaining pressure, as

required, until grout has set.

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4. Pressure Gaugesa. Pressure gauges shall be oil-filled and attached to a saddle-type diaphragm seal to

prevent clogging with cellular concrete.b. All gauges shall be certified and calibrated in accordance with ANSI B40.1, Grade 2A.

D. Mixes

1. Preformed foam shall be generated by combining controlled quantities of air, water andfoaming agent under pressure. Foam shall retain its stability until the cement sets to form aself-supporting matrix. The resulting low density cellular grout shall have essentially closedcell and low water absorptive characteristics.

2. Admixtures may be used to reduce water, to control set time, and to reduce segregationand bleeding. Admixtures that promote steel corrosion will not be permitted. Admixturesshall be specifically approved by foaming agent material manufacturer and shall be inaccordance with their recommendations.

3. Admixture content, batching method and time of introduction to the mix shall be inaccordance with the manufacturer’s recommendations and for compliance with theseSpecifications.

E. Source Quality Control

1. Cement mill test reports shall be provided for every batch of slurry.

2. Sample and test fine aggregate in accordance with ASTM C33, at the frequency specifiedin the approved Quality Control Plan.

3. Sample and test fly ash in accordance with ASTM C311 for every 400 tons used.

4. Provide delivery and measuring of materials from batching equipment to withinaccuracies specified in ASTM C94. Test scales periodically in a manner and at intervals inthe Quality Control Plan.

5. Foam shall be introduced to the slurry by volume of the preformed foam to time. Foamgenerating equipment shall be tested and calibrated each day for dilution percentage, densityand volume output.

6. The batching system shall be capable of maintaining slurry unit weight ±2 percent of thedesign unit weight.

7. Slurry unit weight at the batch plant shall be checked at least twice per hour per ASTMC796, noting the time and temperature.

8. A Mix Design Ticket shall be prepared each day. Tickets shall identify the mix, wet unitweight, and the amount of each material in the mix.

03310-4: EXECUTION

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A. Verification of Conditions

1. Layout: CONTRACTOR shall provide as-built documents and records to the cellularconcrete backfill contractor or consultant before installation.

2. Notification: CONTRACTOR shall notify the OWNER/ENGINEER, in writing, ofunsatisfactory conditions that would cause defective installation or latent defects inworkmanship or curing of the cellular concrete backfill.

3. Acceptance: Proceeding with installation of grout work means acceptance of existingconditions.

B. Preparation

1. Before installation of the carrier pipe, provide protection of fresh cellular concretebackfill from water inflows and/or zones of water seepage in excess of 5 gpm.

2. Upon completion of installation of the carrier pipe, but prior to placement of cellularconcrete backfill, CONTRACTOR shall install a bulkhead at each end and appropriateventing.

C. Placement

1. Batching: Slurry shall be batched mechanically in a manner ensuring consistency of themix. All solids shall be thoroughly wetted before the introduction of the foam. Excessivemixing shall be avoided in order to reduce the possibility of changes in unit weight andconsistency.

2. Mixing: A foam generator shall be used to produce a predetermined quantity of pre-formed foam which shall be injected into the mixer and blended with the cement slurry.Foam shall be introduced per the foam concentrate manufacturer’s recommendations usingapproved foam generating equipment. Continuous generating systems shall be used.

3. Placement

a. Limits of each cellular concrete placement shall be predetermined by theCONTRACTOR based on size and capacity of the batching equipment and initial settime of the proposed cellular grout.

b. At the CONTRACTOR option, bulkheads may be constructed at the end of eachreach of pipe to be backfilled.

i. Bulkheads shall be constructed so the annular space will be completely backfilled.

ii. Bulkheads shall incorporate a minimum 2-inch diameter drain pipe in the invert of thetunnel to facilitate drainage of water during concrete backfilling. This pipe shall besecurely capped and plugged once cellular concrete backfill begins to flow from thedrain line.

iii. An opening shall be provided in the tunnel crown to allow entrapped air to escape.Vent outlets shall be provided as required.

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c. The placement of cellular concrete backfill shall be by means of outlets in thefinal tunnel liner (carrier pipe). The size of the outlets shall be as shown on thePLANS or as determined by the CONTRACTOR and pipe manufacturer. i. Placement of cellular concrete at any outlet shall not exceed the

period of time equal to the initial set time of the proposed mix.

ii. Placement of lifts or stages of cellular concrete on a previous lift ofcellular concrete shall be delayed a minimum of 12 hours.

d. Backfilling of the annular space shall be accomplished by placing the concrete inmultiple lifts. Alternatively, monolithic placement procedures may be used, provided theCONTRACTOR demonstrates that this technique will not induce flotation orunacceptable deformation of the carrier pipe.

e. For multiple lifts, the following shall apply:

i. Connect multiple 2-inch minimum I.D. grout hoses to opposingoutlets in the springline. Use two hoses injecting concrete simultaneously to preventside movement of the pipe.

ii. Inject concrete until flow is visible at the next pair of outletsdownstream to ensure a fairly level lift.

iii. A full reach of tunnel shall be completed in one lift before thesecond lift (topping-out concrete) is injected. For the topping-out lift, follow theprocedure given in Subparagraph f.

f. For monolithic or topping-out lifts, the following shall apply:

i. Utilize outlets located in the crown of the tunnel. Monolithic liftsshall utilize springline outlets for inspection.

ii. Connect single or multiple 2-inch minimum I.D. grout hose(s) tooutlets in the tunnel lining.

iii. Inject cellular concrete until either maximum allowable pressure isachieved, or concrete flows from the next outlet downstream, or until the maximuminjection time is achieved (initial design set time or viscosity change).

iv. Advance the injection point by connecting a minimum of oneoutlet downstream from where the concrete has been seen in the crown. Repeat theprocess, ensuring no air will be trapped in the annular space.

v. Start each day’s work by drilling holes in the crown of the tunneluntil the end of the previous day’s flow is determined. Start injection at the beginningof this void and repeat the injection procedure. Plug the hole as recommended by thepipe manufacturer.

g. The gauged pumping pressure shall not exceed the liner pipe manufacturer’srecommendations.

h. The CONTRACTOR shall maintain a supply of water in the tunnel at the locationof the cellular concrete backfilling operation to facilitate flushing of injection lines oroutlets.

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D. Field Quality Control

1. Unit Weight Measurement: Cellular concrete shall be tested for unit weight at the pointof injection (placement), in accordance with ASTM C567, every 30 minutes and for eachbatch that is sampled for compression test. The unit weight of the cellular concrete at thepoint of placement shall be within 2 percent of the design unit weight.

2. Compression Test Cylinders: One set of four compression test cylinders (3-inch by6-inch) shall be cast for every 200 cubic yards of cellular concrete, with a minimum of 2 setsper day. Test cylinders shall be sampled at the point of injection in accordance with ASTMC495. If fly ash is used, two additional sets will be taken each day. Cylinders shall be castin styrofoam molds; plastic molds are not permitted. Care shall be taken to ensure thatcylinder samples are not jostled or moved prior to the initial set.

3. Compression Testing: Two cylinders shall be tested at an age of 7 days and theremaining two cylinders shall be tested at an age of 28 days. If fly ash is used, two additionalcylinders shall be tested at 56 days. Cellular concrete shall be tested for unconfinedcompressive strength in accordance with ASTM C495. For testing, cylinders shall be cappedwith Plaster of Paris; sulfur caps are not permitted. Evaluation and acceptance of test resultsshall be per ACI 214.

4. Batching and placement shall cease immediately if the mix does not meet the design unitweight. Corrective actions shall be taken before recommencing batching and placement.

5. Documentation: A Pour Report and a Mix Design Ticket shall be prepared each day andbe distributed to the ENGINEER.

E. Cleaning

1. Equipment shall be maintained and cleaned thoroughly each day. Hydrocarbons shall beprohibited from entering the pumping chamber.

2. On completion of each cellular concrete placement, wash down the tunnel lining.

3. On completion of all the cellular concrete backfill, remove all waste material, spilledgrout or concrete, and all timber and construction debris. Leave the tunnel in a cleancondition.

03310-5: MEASUREMENT AND PAYMENT

Work performed and materials furnished as prescribed by this item will not be measured nor paidfor directly but shall be considered subsidiary to Contract bid items. Include cost of same inContract price bid for work of which this is a component part.

END OF SECTION

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ITEM 5066

CENTRIFUGALLY CAST FIBERGLASS REINFORCED POLYMERMORTAR PIPE AND FITTINGS FOR 24 “ WASTEWATER MICROTUNNEL

CONSTRUCTION

PART 1- GENERAL

1.01 SUMMARY

A. 24” Centrifugally Cast Fiberglass Reinforced Polymer Mortar (CCRP) Pipe forinstalla- tion in the microtunnel and open cut.

1.02 RELATED REQUIREMENTS (NOT USED)

1.03 REFERENCES

The publications listed below form a part of this Specification to the extent referenced. The publications are referred to in the text by basic designation only.

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D3262 Standard Specification for "Fiberglass"(Glass-Fiber-Reinforced Thermo- setting Resin) Sewer Pipe

ASTMD3681 Method for Determining Chemical Resistance ofReinforced Thermo- setting Resin Pipe in Deflected Condition

ASTMD4161 Specification for "Fiberglass" (Glass-Fiber-Reinforced)Thermosetting Resin Pipe Joints Using Flexible Elastomeric Seals

1.04 - 1.05 (NOT USED)

1.06 SUBMITTALS

A. Provide sufficient data for the ENGINEER to properly evaluate the pipe for use on this Project.

B. Product data submittals shall include the following, as a minimum: 1. Details of the proposed pipe. 2. Properties and strengths of the pipe, including maximum allowable jacking loads. 3. Details of pipe joints to be used. 4. Pipe design analysis to demonstrate the ability of the pipe to support the jacking loads and the soil loads on the pipe. The analysis shall be done in accordance

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with ring deflection requirements of TNRCC 30 TAC, Chapter 317.20 pertaining to flexible pipe, and be prepared by a Professional Engineer, registered in the State of Texas, who is fully aware of the characteristics of Centrifugally Cast Fiberglass Reinforced Polymer Mortar Pipe. The pipe deflection calculations shall ensure that predicted deflection will be less than 5 percent under long-term loading conditions (soil prism load) for the highest density of soil overburden and surcharge loads. Deflection on calculations shall be prepared using long-term report for the Project, or other site-specific data obtained by the CONTRACTOR as approved by the ENGINEER.

5. Instructions on storage, handling, transporting and installation. 6. Standard catalog sheets.

D. Test Reports: Provide test reports certifying that the pipe has been tested inaccordance with and exceeds minimum requirements of ASTM D3262 and ASTM D3681.

1.07 -1.11 (NOT USED)

PART 2 - PRODUCTS2.01 MANUFACTURERS

Hobas Pipe USA, Inc. or approved equal.

2.02 MATERIALS

A.Resin Systems: The manufacturer shall use only polyester resin systems with a proven history of performance in this particular application. The historical data shall have been collected from applications of a composite material of similar construction and composition as the proposed product.

B. Glass Reinforcements: The reinforcing glass fibers used to manufacture the components shall be of commercial grade glass filaments with binder and sizing compatible with impregnating resins.

C. Fillers: Silica sand or other suitable materials may be used.

D. Additives: Resin additives, such as pigments, dyes, and other coloring agents, if used, shall in no way be detrimental to the performance of the product nor shall they impair visual inspection of the finished products.

E.Rubber Gaskets: Gaskets shall be of elastomeric materials supplied by approved gasket manufacturers and be suitable for the service intended. Gaskets shall either be affixed to the pipe by means of a suitable adhesive or shall be installed in such a manner to prevent the gasket from rolling out of the pipe's pre-cut groove.

F.The internal liner resin shall be suitable for service as sewer pipe, and shall be highly resistant to exposure to sulfuric acid as produced by biological activity from hydrogen

sulfide gases, solvents and other hydrocarbons. Pipe shall meet or exceed requirements

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of ASTM D3681.

2.03 FABRICATION

A. Pipes 1. Furnish pipes in the diameters shown on PLANS and within the tolerances

specified below.

2. Manufacture pipe by the centrifugal casting process to result in a dense, nonorous, corrosion-resistant, consistent composite structure to meet the operating conditions as shown on the PLANS.

3. Use of stiffening ribs or rings is not acceptable.

B. Pipe Joints and Couplings: Unless otherwise specified, the pipe shall be field connected with fiberglass sleeve couplings that utilize elastomeric sealing gaskets as the sole means

to maintain joint watertightness. The joints must meet the performance requirements of ASTM D4161. The couplings shall be designed for the maximum jacking loads to be used. Jacking loads shall not exceed those acceptable to the pipe manufacturer.

C. Fittings: Flanges, elbows, reducers, tees and other fittings shall be capable of withstanding operating conditions when installed. They may be contact molded or manufactured from mitered sections of pipe joined by glass fiber reinforced overlays.

C. Manhole Connections: Provide a water stop flange (wall pipe) for connection to proposedmanholes as indicated on the PLANS.

2.04 SOURCE QUALITY CONTROL

A. Dimensions1. Diameters: The actual outside diameter of the pipes shall be in accordance with Table 3 of ASTM D3262.

2. Lengths: The pipe standard length will be approximately 20 feet. A maximum of 10 percent of the lengths, excluding special order pipes, may be supplied in random lengths. 3. Wall Thickness: The minimum average wall thickness shall be the design thickness required for the soil loads as determined in Paragraph 1.06 C.4 of this Section. The minimum single point thickness shall not be less than 90 percent of the stated design thickness. 4. End Squareness: Pipe ends shall be square to the pipe axis. 5. Tolerance of Fittings: The tolerance of the angle of an elbow and the angle between the main and leg of a wye or tee shall be +2 degrees. The tolerance on the laying length of a fitting shall be +2 inches.

B. StifffiessClasses1. Stifffiess class of FRP pipe shall satisfy design requirements. The minimum nominal pipe wall thickness is 1.93 inches and the minimum pipe thickness at the gasketed groove is 1.18 inches. Jacking operations and methods shall be as required to not exceed jacking loads of 450 tons with a safety factor of 3. Submit

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design calculations as required in Paragraph 1.06 of this Section. C. Testing 1. Pipes shall be tested in accordance with ASTM D3262. 2. Pipe joints shall be qualified per the tests of Section 7 of ASTM D4161.

D. Customer Inspection 1. The OWNER/ENGINEER shall be entitled to inspect pipes or witness the pipe manufacturing. Such inspection shall not relieve the manufacturer of the responsibilities to provide products that comply with the applicable standards and these Specifications. 2. Manufacturer's Notification to Customer: Should the OWNER/ENGINEER wish

to see specific pipes during any phase of the manufacturing process, the manufacturer must provide the OWNER/ENGINEER with adequate advance notice of when and where the production of the pipes will take place.

E. Failure to Inspect: Should the OWNER/ENGINEER elect not to inspect the manu- facturing, testing, or finished pipes, it in no way implies approval of products or tests.

F. Packaging, Handling and Shipping: Packing, handling and shipping should be done in accordance with the manufacturer's instructions. Damaged pipe shall be immediately removed from the construction site, unless repaired by the manufacturer to the complete

satisfaction of the OWNER or his on-site representatives.

PART 3 - EXECUTION

3.01 - 3.02 (NOT USED)

3.03 INSTALLATION

A. The installation of pipe and fittings in the tunnel shall be in accordance with requirements of applicable Specification Sections.

B. The manufacturer must supply a suitable qualified field service representative to be present periodically during the installation of pipe.

C. Pipe Handling: Use textile slings.

D. Jointing 1. Clean ends of pipe and coupling components. 2. Check pipe ends and couplings for damage. Correct any damage found. 3. Coupling grooves must be completely free of dirt. 4. Apply joint lubricant to pipe ends and rubber seals of coupling. Use only lubricants approved by the pipe manufacturer. 5. Use suitable auxiliary equipment, such as a wire rope puller, to pull pipe joints together. 6. Do not exceed forces recommended by the manufacturer for coupling pipe. If excessive force is required, remove coupling, deterrnine source of problem, and correct it.

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7. In the process of jointing the pipe, do not allow the deflection angle to exceed the deflection permitted by the manufacturer.

E. If the pipe is cut in the field or the interior lining is disturbed, recoat the interior with a similar quantity and quality of the liner resin.

3.04 REPAIR/RESTORATION (NOT USED)3.05 FIELD QUALITYCONTROL

A. Tests: Conform to testing requirements in Paragraph 3.03 of Section 02687, "Testing of Installed Piping Systems".

3.06 - 3.10 (NOT USED)

3.11 MEASUREMENT AND PAYMENT

No separate measurement or payment for work performed under this Section but shall beconsidered subsidiary to Contract bid items. Include cost of same in Contract price bid for work of which this is acomponent part.

END OF SECTION