project table of contents division 00 - … · division 00 - procurement and contracting...

FTQW05-4801IMFH Phase 2, Eielson AFB, Alaska

PROJECT TABLE OF CONTENTS

DIVISION 00 - PROCUREMENT AND CONTRACTING REQUIREMENTS

00 22 13 SUPPLEMENTARY INSTRUCTIONS TO BIDDERS

DIVISION 01 - GENERAL REQUIREMENTS

01 11 00 SUMMARY OF WORK01 14 00 EXISTING UTILITIES01 30 00 ADMINISTRATIVE REQUIREMENTS01 33 00 SUBMITTAL PROCEDURES01 35 43 SAFETY, ENVIRONMENTAL PROTECTION, REGULATIONS, AND CODES01 42 00 SOURCES FOR REFERENCE PUBLICATIONS01 45 04.00 10 CONTRACTOR QUALITY CONTROL01 50 02.00 10 TEMPORARY CONSTRUCTION FACILITIES01 57 20.00 10 ENVIRONMENTAL PROTECTION01 77 00.00 20 CLOSEOUT PROCEDURES01 78 00.00 40 CLOSEOUT SUBMITTALS01 78 23 OPERATION AND MAINTENANCE DATA

DIVISION 02 - EXISTING CONDITIONS

02 24 27 FIELD SCREEN TESTING OF SOILS FOR POL CONTAMINATION02 41 00 DEMOLITION AND DECONSTRUCTION02 82 14.00 10 ASBESTOS HAZARD CONTROL ACTIVITIES02 82 33.13 20 REMOVAL/CONTROL AND DISPOSAL OF PAINT WITH LEAD02 83 13.00 20 LEAD IN CONSTRUCTION02 84 16 HANDLING OF LIGHTING BALLASTS AND LAMPS CONTAINING PCBs

AND MERCURY02 84 33 REMOVAL AND DISPOSAL OF POLYCHLORINATED BIPHENYLS (PCBs)

DIVISION 03 - CONCRETE

03 30 04 CONCRETE FOR MINOR STRUCTURES

DIVISION 04 - MASONRY

04 20 00 MASONRY

DIVISION 05 - METALS

05 50 00 METAL: MISCELLANEOUS AND FABRICATIONS

DIVISION 06 - WOOD, PLASTICS, AND COMPOSITES

06 10 00 ROUGH CARPENTRY06 20 00 FINISH CARPENTRY06 61 16 SOLID POLYMER (SOLID SURFACING) FABRICATIONS

DIVISION 07 - THERMAL AND MOISTURE PROTECTION

07 11 13 BITUMINOUS DAMPPROOFING07 21 13 BOARD AND BLOCK INSULATION07 21 16 MINERAL FIBER BLANKET INSULATION07 31 13 ASPHALT SHINGLES07 46 19.00 40 EXTERIOR SIDING - BID OPTION #107 46 46 FIBER-CEMENT SIDING07 60 00 FLASHING AND SHEET METAL



07 84 00 FIRESTOPPING07 92 00 JOINT SEALANTS

DIVISION 08 - OPENINGS

08 11 13 STEEL DOORS AND FRAMES 08 14 00 WOOD DOORS08 36 13 SECTIONAL OVERHEAD DOORS08 53 00 PLASTIC WINDOWS08 71 00 DOOR HARDWARE08 81 00 GLAZING

DIVISION 09 - FINISHES

09 22 00 METAL SUPPORT ASSEMBLIES09 29 00 GYPSUM BOARD09 30 00 CERAMIC TILE, QUARRY TILE, AND PAVER TILE09 62 19.11 DECORATIVE LAMINATE FLOORING09 65 00 RESILIENT FLOORING09 68 00 CARPET09 90 00 PAINTS AND COATINGS

DIVISION 10 - SPECIALTIES

10 14 01 EXTERIOR SIGNAGE10 28 13 TOILET ACCESSORIES10 44 16 FIRE EXTINGUISHERS10 55 20 POSTAL SPECIALTIES

DIVISION 11 - EQUIPMENT

11 31 00 RESIDENTIAL APPLIANCES11 68 13 PLAYGROUND EQUIPMENT

DIVISION 12 - FURNISHINGS

12 20 00 HORIZONTAL LOUVER BLINDS12 35 30.00 10 RESIDENTIAL CABINETS AND COUNTERTOPS12 93 00 SITE FURNISHINGS

DIVISION 13 - SPECIAL CONSTRUCTION

13 48 00.00 10 SEISMIC PROTECTION FOR MECHANICAL EQUIPMENT13 48 00 SEISMIC PROTECTION FOR MISCELLANEOUS EQUIPMENT

DIVISION 14 - Not Used


DIVISION 22 - PLUMBING

22 00 00 PLUMBING, GENERAL PURPOSE

DIVISION 23 - HEATING, VENTILATING, AND AIR CONDITIONING

23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS23 03 00.00 20 BASIC MECHANICAL MATERIALS AND METHODS23 05 93.00 10 TESTING, ADJUSTING, AND BALANCING OF HVAC SYSTEMS23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS



23 08 00.00 10 COMMISSIONING OF HVAC SYSTEMS23 57 10.00 10 FORCED HOT WATER HEATING SYSTEMS USING WATER AND STEAM

HEAT EXCHANGERS


DIVISION 26 - ELECTRICAL

26 00 00.00 20 BASIC ELECTRICAL MATERIALS AND METHODS26 05 19.00 10 INSULATED WIRE AND CABLE26 05 48.00 10 SEISMIC PROTECTION FOR ELECTRICAL EQUIPMENT26 08 00 APPARATUS INSPECTION AND TESTING26 12 19.10 THREE-PHASE PAD-MOUNTED TRANSFORMERS26 12 19.20 SINGLE-PHASE PAD-MOUNTED TRANSFORMERS26 20 00 INTERIOR DISTRIBUTION SYSTEM26 29 23 VARIABLE FREQUENCY DRIVE SYSTEMS UNDER 600 VOLTS26 51 00 INTERIOR LIGHTING26 56 00 EXTERIOR LIGHTING

DIVISION 27 - COMMUNICATIONS

27 05 14.00 10 CABLE TELEVISION PREMISES DISTRIBUTION SYSTEM27 10 00 BUILDING TELECOMMUNICATIONS CABLING SYSTEM

DIVISION 28 - ELECTRONIC SAFETY AND SECURITY

28 31 74.00 20 INTERIOR FIRE DETECTION AND ALARM SYSTEM

DIVISION 31 - EARTHWORK

31 00 00 EARTHWORK31 05 19 GEOTEXTILE31 11 00 CLEARING AND GRUBBING

DIVISION 32 - EXTERIOR IMPROVEMENTS

32 05 33 LANDSCAPE ESTABLISHMENT32 13 18 BASE COURSE AND BITUMINOUS PAVING FOR VEHICLE TRAFFIC

AREAS32 16 13 CONCRETE SIDEWALKS AND CURBS AND GUTTERS32 18 16.13 PLAYGROUND PROTECTIVE SURFACING32 31 00 FENCING32 92 19 SEEDING32 93 00 EXTERIOR PLANTS

DIVISION 33 - UTILITIES

33 17 11 WATER DISTRIBUTION SYSTEMS IN UTILIDORS33 31 17 SEWERS IN UTILIDORS33 40 01 STORM DRAINAGE33 57 12 HEAT DISTRIBUTION SYSTEMS IN UTILIDORS AND MANHOLES33 60 02 UTILIDOR SYSTEM33 71 01 OVERHEAD TRANSMISSION AND DISTRIBUTION33 71 02.00 20 UNDERGROUND ELECTRICAL DISTRIBUTION








DIVISION 43 - PROCESS GAS AND LIQUID HANDLING, PURIFICATION, AND STORAGE EQUIPMENT

43 02 00 WELDING PRESSURE PIPING




-- End of Project Table of Contents --



SECTION 33 17 11

WATER DISTRIBUTION SYSTEMS IN UTILIDORS

PART 1 GENERAL

1.1 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.

ASTM INTERNATIONAL (ASTM)

ASTM A 53 (2004) Pipe, Steel, Black and Hot-Dipped,

Zinc-Coated, Welded and Seamless ASTM A 36 (1996) Carbon Structural Steel ASTM A 47 (1999) Ferritic Malleable Iron Castings ** ASTM A 536 (1984; R 2004) Ductile Iron Castings ASTM C 518 (2002) Steady-State Heat Flux Measurements

and Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus

ASTM C 552 (2003) Cellular Glass Thermal Insulation ASTM C 578 (2006) Rigid, Cellular Polystyrene Thermal

Insulation ASTM D 1621 (1994) Compressive Properties of Rigid

Cellular Plastics ASTM D 1668 (1997a) Glass Fabrics (Woven and Treated)

for Roofing and Waterproofing ASTM D 2842 (1997) Water Absorption of Rigid Cellular

Plastics ASTM D 4586 (2000) Asphalt Roof Cement, Asbestos Free

ASME INTERNATIONAL (ASME)

ASME INTERNATIONAL (ASME) ASME B16.1 (2005) Cast Iron Pipe Flanges and Flanged

Fittings Classes 25, 125, and 250

AMERICAN WATER WORKS ASSOCIATION(AWWA) AWWA B300 (2004) Hypochlorites

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AWWA B301 (2004) Liquid Chlorine

AWWA C110 (1998) Ductile-Iron and Gray-Iron Fittings, 3 In. Through 48 In. (75 mm through 1200 mm), for Water and Other Liquids

AWWA C111 (2000) Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings

AWWA C115 (1999) Flanged Ductile-Iron Pipe With

Ductile-Iron or Gray-Iron Threaded Flanges AWWA C151 (2002) Ductile-Iron Pipe, Centrifugally

Cast, for Water AWWA C500 (1993; C500a) Metal-Seated Gate Valves for

Water Supply Service

AWWA C502 (2005) Dry-Barrel Fire Hydrants

AWWA C600 (2005) Installation of Ductile-Iron Water Mains and Their Appurtenances

AWWA C606 (2004) Grooved and Shouldered Joints AWWA C651 (2005) Disinfecting Water Mains AWWA C205 (2000) Cement-Mortar Protective Lining and

Coating for Steel Water Pipe - 4 In. (100 mm) and Larger - Shop Applied

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS FF-B-575 (Rev C) Bolts, Hexagon and Square FS FF-N-836 (Rev D; Am-3) Nut: Square, Hexagon, Cap,

Slotted, Castle, Knurled, Welding and Single Ball Seat

FS SS-C-153 (Rev C) Cement, Bituminous, Plastic FS TT-E-489 (Rev J; Notice 1)) Enamel, Alkyd, Gloss,

Low Voc Content FS TT-P-19 (Rev D) Paint, Latex (Acrylic Emulsion,

Exterior Wood and Masonry) FS TT-P-641 (Rev G; Am-1) Primer Coating, Zinc

Dust-Zinc Oxide (for & Am-1 Galvanized Surfaces)

FS WW-U-531 (Rev F) Unions, Pipe, Steel or Malleable

Iron: Threaded Connection, 150 Lb, 250 Lb and 300 Lb WSP

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U.S. GENERAL SERVICES ADMINISTRATION (GSA)

MILITARY SPECIFICATIONS (MS) MS MIL-E-17813 (Rev F) Expansion Joints, Pipe, Metallic

Bellows MS DOD-P-21035 (Rev B) Paint, High Zinc Dust Content,

Galvanizing Repair (Metric) MS MIL-P-26915 (Rev C) Primer Coating, Zinc Dust

Pigmented, for Steel Surfaces

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)

MSS SP-58 (2002) Pipe Hangers and Supports -

Materials, Design and Manufacture MSS SP-69 (2003) Pipe Hangers and Supports -

Selection and Application MSS SP-80 (2003) Bronze Gate, Globe, Angle and Check

Valves

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) NFPA 24 (1995) Installation of Private Fire

Service Mains and Their Appurtenances NFPA 325-1 (1994) Fire Hazard Properties of Flammable

Liquids, Gases, and Volatile Solids NFPA 49 (1994) Hazardous Chemicals Data NFPA 704 (1996) Identification of the Fire Hazards

of Materials for Emergency Response

THE SOCIETY FOR PROTECTIVE COATINGS (SSPC) SSPC Paint 25 (1997; E 2004) Zinc Oxide, Alkyd, Linseed

Oil Primer for Use Over Hand Cleaned Steel, Type I and Type II

STATE OF ALASKA ADMINISTRATIVE CODE (AAC)

18 AAC 80 (2006) Drinking Water

1.2 GENERAL This section covers water distribution lines, water service lines, connections to building services as shown on the drawings, fire lines and fire hydrants.

The Contractor shall obtain the construction certification as required by the Alaska Department of Environmental Conservation (ADEC) under 18 AAC 80.200. The Contractor's construction certification works shall include the record drawings, the observing engineer, and signing the certificate of construction form. In addition, the Contractor shall obtain any ADEC

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required interim permits as well as the final permit to operate the system. 1.2.1 Piping for Water Distribution Lines Piping for water distribution lines shall be cement lined ductile iron, unless otherwise shown or specified.

1.2.2 Piping for Water Service Lines Piping for water service lines less than 4 inches in diameter shall be galvanized steel, unless otherwise shown or specified. Piping for water service lines for sizes 4 inches and larger shall be cement lined ductile iron, unless otherwise shown or specified.

1.2.3 Piping for Fire Lines Piping for fire lines shall be cement lined ductile iron.

1.2.4 Standard Products The equipment to be furnished under this specification shall be essentially the standard product of the manufacturer. Where two or more units of the same class of equipment are required, these units shall be the products of a single manufacturer; however, the component parts of the system need not be the products of the same manufacturer. The products of any reputable manufacturer regularly engaged in the commercial production of water distribution equipment will not be excluded on the basis of minor differences, provided all essential requirements of this specification relative to materials, capacity and performance are met.

1.3 SUBMITTALS Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Water Distribution System; G

SD-03 Product Data

Materials Manufacturer's descriptive data, catalog cuts, and brochures for each type and size of the following:

a. Alignment guides.

b. Expansion joints.

c. Hangers.

d. Couplings and gaskets.

e. Pipe.

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f. Valves.

g. Fire hydrants.

h. Fittings.

Calculation of Pipe Supports; G

Calculation of Pipe Anchors; G

Calculation of pipe supports and pipe anchors shall be submitted with support system descriptive data.

SD-06 Test Reports

Hydrostatic Tests, G

Disinfection; G

SD-08 Manufacturer's Instructions

Manufacturer's Recommendations

Manufacturer's recommendations for each material or procedure to be utilized which is required to be in accordance with such recommendations. The Contractor shall have a copy of the manufacturer's instructions available at the construction site at all times and shall follow these instructions unless otherwise directed by the Contracting Officer.

1.4 SUBMITTAL SUPPLEMENTAL

See paragraphs below for further descricptions of submittals required by paragraph SUBMITTALS:

1.4.1 Water Distribution System

Detail drawings for alignment guides, anchors, expansion joints, flanges, gaskets, hangers and supports, insulation, pipe, and valves, including a complete list of equipment and material, manufacturer's descriptive and technical literature, catalog cuts, and installation instructions. Drawings shall contain complete pipe stress calculations for all expansion joints and any other details required to demonstrate that the system has been coordinated and will properly function as a unit. Drawings shall show proposed system layout, provisions for expansion, pipe anchors and guides, and layout and anchroage of equipment and appurtenances in valve manholes, and equipment relationship to other parts of the work including clearances for maintenance and operation.

Any supports, anchors, guides, expansion joinst, etc., for the piping system shown on the drawings are generic only. The Contractor shall be responsible for the design of the piping system and shall submit design calculations and shop drawings for the piping system. Design shall meet requirements of these specifications including, but not limited to material size, quality, and finish. Calculations shall be stamped and signed by an engineer registered in the State of Alaska.

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1.4.2 Materials

Manufacturer's descriptive data, catalog cuts, and brochures for each type and size of the following: alignment guides, expansion joints, hangers, couplings, gaskets, pipe, valves, fire hydrants, and fittings.

1.4.3 Calculation of Pipe Supports

Calculation of pipe supports shall be submitted with support system descriptive data, see submittal in Section 33 60 02 UTILIDOR SYSTEM.

1.4.4 Calculation of Anchors

Calculation of pipe anchors shall be submitted with anchor sizes and drawings showing locaion and details of anchor. At a minimum, anchors shall be placed near the locations shown on the drawings.

1.4.5 Manufacturer's Recommendations

Manufacturer's recommendations for each material or procdure to be utilized which is required to be in accordance with such recommendations. The Contractor shall have a copy of the manufacturer's instructions available at the construction site at all times and shall follow these instructions unless otherwise directed by the Contracting Officer.

1.4.6 Hydrostatic Tests

Submit a hydrostatic test procedure describing method including method proposed for disposal of wastewater.

1.4.7 Disinfection

Submit a disinfection and test procedure describing method of disinfection with drawings showing proposed flush points, proposed chlorine injection points, method for disposal of wastweater and proposed sampling locations 30 days prior to disinfection. Submit satisfactory test results conducted by a laboratory certified by the state of Alaska.

PART 2 PRODUCTS 2.1 MATERIALS Materials shall conform to the respective specifications and other requirements specified below: Pipe and fittings which are connected to anchors shall be steel.

2.2 PIPE

2.2.1 Ductile-Iron Pipe AWWA C151, working pressure not less than 150 psi unless otherwise shown or specified. Pipe shall be cement-mortar lined and asphalt coated in accordance with AWWA C151. Pipe size 4" and larger.

2.2.2 Galvanized Steel Pipe

ASTM A 53, Schedule 40, Galvanized. Pipe size 2" and smaller.

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2.3 JOINTS 2.3.1 Ductile-Iron Pipe 2.3.1.1 Mechanical Joints Mechanical joints shall be of the restrained stuffing box type and shall conform to AWWA C111 as modified by AWWA C151. Restrained joints shall be of the type that cannot be separated without failure of the pipe joint material. Pipe joints shall not rely on friction between metal-to-metal contact surfaces for restraint. Set-screw type joints will not be permitted.

2.3.1.2 Restrained Push-On Joint Fittings Restrained push-on joint fittings for ductile iron pipe and fittings shall be TR Flex Fittings as manufactured by U.S. Pipe or Flex-Ring Fittings as manufactured by American Pipe, or equal.

2.3.1.3 Grooved and Shouldered Joints

AWWA C606 mechanically connected, grooved and shouldered joints.

2.3.1.4 Rubber Gaskets and Lubricant Rubber gaskets and lubricant shall conform to the applicable requirements of AWWA C111.

2.3.1.5 Flanges Flanges shall conform to AWWA C115 and/or AWWA C110.

2.3.2 Flange Gaskets All flanges shall be provided with 1/8 inch thick rubber gaskets.

2.4 INSULATING JOINTS Insulating joints shall be installed between ferrous and nonferrous metallic pipe, fittings, and valves. Insulating joints shall consist of a sandwich-type flange insulating gasket of the dielectric type, insulating washers, and insulating sleeves for flange bolts. Insulating gaskets shall be full faced with outside diameter equal to the flange outside diameter. Bolt insulating sleeves shall be full length. Units shall be of a shape to prevent metal-to-metal contact of dissimiliar metallic piping elements. Joints shall be suitable for the required working pressure.

2.5 FITTINGS AND SPECIALS Fittings and specials for ductile-iron pipe and steel pipe may be interchanged where applicable. Mating surfaces between steel and iron flanges shall be plain faced. Protective materials for fittings and specials that cannot be mechanically lined and coated shall be lined and coated by hand, using the same materials as are used for the pipe with the same number of applications of each material carefully and smoothly applied.

2.5.1 For Ductile-Iron Pipe Fittings and specials shall have a pressure rating no less than that of

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adjoining pipe, unless otherwise specified. Fittings and specials for flanged joint pipe shall conform to AWWA C110. Fittings required on the drawings which are not covered in AWWA C110 shall have AWWA flanges and be based on AWWA C110 design principles. Fittings and specials for grooved and shouldered end pipe shall conform to AWWA C606 without field preparation. Malleable iron shall be ASTM A 47. Ductile iron shall be ASTM A 536.

2.5.2 Unions Unions on pipe less than 4 inches shall conform to FS WW-U-531, Type B.

2.6 COUPLINGS 2.6.1 Mechanical Couplings Mechanical couplings for ductile iron pipe shall be either the sleeve type or the split sleeve type. Couplings shall provide a tight flexible joint under all reasonable conditions, such as pipe movements caused by expansion, contraction, slight settling or shifting on pipe supports, and vibrations. Couplings shall be of strength not less than the adjoining pipeline.

2.6.1.1 Split-Sleeve-Type Couplings Split-sleeve-type couplings shall be in accordance with AWWA C606. Gaskets shall also have a triple seal which is strengthened by line pressure and is designed with a soft internal ring or a projecting center rib which extrudes into the gap at the pipe ends as the housings are tightened, to seal off the gasket cavity. Couplings shall be as manufactured by Gustin-Bacon of Lawrence, Kansas, or equal.

2.6.1.2 Sleeve-Type Couplings Sleeve-type couplings shall be used for joining plain end pipe sections. The couplings shall consist of one steel middle ring, two steel followers, two gaskets, and the necessary steel bolts and nuts to compress the gaskets. Couplings shall have positive restraint.

2.7 VALVES 2.7.1 Check Valves Check valves shall be designed for a minimum working pressure of 150 psi or as indicated. Valves shall have a clear waterway equal to the full nominal diameter of the valve. Valves shall open to permit flow when inlet pressure is greater than the discharge pressure, and shall close tightly to prevent return flow when discharge pressure exceeds inlet pressure. The size of the valve, working pressure, manufacturer's name, initials, or trademark shall be cast on the body of each valve.

2.7.1.1 Valves 2 Inches and Smaller Valves 2 inches and smaller shall be all bronze designed for screwed fittings, and shall conform to MSS SP-80, Class 150, Types 3 and 4 as suitable for the application.

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2.7.1.2 Valves Larger Than 2 Inches Valves larger than 2 inches shall be iron body, bronze mounted, shall have flanged ends, and shall be the non-slam type. Flanges shall be the 125-pound type conforming to ASME B16.1.

2.7.2 Gate Valves Gate valves shall be designed for a working pressure of not less than 150 psi. Valve connections shall be as required for the piping in which they are installed. Valves shall have a clear waterway equal to the full nominal diameter of the valve, and shall be opened by turning counterclockwise. The operating nut or wheel shall have an arrow cast in the metal, indicating the direction of opening.

2.7.2.1 Valves Smaller Than 3 Inches Valves smaller than 3 inches shall be all bronze and shall conform to MSS SP-80, Type 1, Class 150.

2.7.2.2 Valves 3 Inches and Larger Valves 3 inches and larger shall be iron body, bronze mounted, and shall conform to AWWA C500.

2.7.3 Combination Air Valves

Combination air valves shall be single housing, combining both an air/vacuum relief valve and an air release valve. The air/vacuum portion shall automatically exhaust large quantities of air during filling of the pipeline and automatically relieve vacuum during draining of the pipeline. The air/vacuum large orifice size shall be 2 inches. The air release portion shall automatically release small pockets of air that collect during operation. The small orifice size shall be 3/32 inch. Valves shall be cast iron body or aluminum body; bronze, stainless steel or cast iron trim, with stainless steel or plastic float, as manufactured by Val-Matic Valve and Manufacturing Corp., Elmhurst, IL, or equal.

2.8 FIRE HYDRANTS

Fire hydrants shall conform to AWWA C502. Hydrants shall have a 6-inch bell connection, two 2-1/2 inch hose connections and one 4-1/2 inch pumper connection. Outlets shall have American National Standard fire-hose coupling threads. Working parts shall be bronze. Design, material and workmanship shall be similar and equal to the latest stock pattern ordinarily produced by the manufactuer. The exterior of fire hydrants below the breakable coupling shall be painted as specified for pipes inside the utilidor, with the added requirement of two (total) coats of the asphalt varnish. The exterior above the coupling shall be painted with one coat of red-iron oxide paint conforming to SSPC Paint 25, and two finish coats of alkyd enamel conforming to FS TT-E-489. The finish coats shall be base architectural standard bronze. Hydrants shall be dry-barrel type conforming to AWWA C502 with valve opening at least 5 inches in diameter.

2.9 DISINFECTION Chlorinating materials shall conform to the following:

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Chlorine, Liquid: AWWA B301.

Hypochlorite, Calcium and Sodium: AWWA B300. 2.10 COLD GALVANIZING COMPOUND Either MS DOD-P-21035; MS MIL-P-26915, Type I; or FS TT-P-641.

2.11 MASTIC Mastic shall conform to either ASTM D 4586, Type I; or FS SS-C-153, Type I, Class B or Type II. Mastic shall be compatible with intended use.

2.12 CELLULAR GLASS INSULATION Cellular glass insulation shall meet the requirements of ASTM C 552.

2.13 GLASS CLOTH Glass cloth shall conform to ASTM D 1668 and be of the type recommended by the manufacturer for the intended use.

2.14 LATEX PAINT FS TT-P-19.

2.15 COAL-TAR COATING Coal-tar coating shall be as specified in SECTION 33 60 02 UTILIDOR SYSTEM.

2.16 EXTRUDED POLYSTYRENE INSULATION Extruded polystyrene insulation shall conform to ASTM C 578, Type V, VI, or VII.

2.17 POLYURETHANE AND POLYISOCYANURATE INSULATION The manufacture of polyurethane and/or polyisocyanurate shall be based on the reaction of an isocyanurate with a polyol using a fluorocarbon blowing agent to form a rigid closed-cell structured polyurethane foam, or on the reaction of an isocyanurate with itself using a catalyst and a blowing agent to form a rigid closed-cell structured polyisocyanurate foam. The insulation foam shall be homogeneous, of uniform density and self-extinguishing. The insulation shall have the following properties:

Compressive Strength 20 psi (min.) by ASTM D 1621 @74 deg F Initial Thermal Conductivity 0.014 BTU/(hr.ft. deg F) (max.) K value @ 75 deg F by ASTM C 518 Moisture Absorption 3% by volume (max.) by ASTM D 2842 2.18 SERVICE CLAMPS Service clamps shall have a pressure rating not less than that of the pipe

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to be connected and shall be either the single or double flattened strap type. Clamps shall have a galvanized malleable iron body with cadmium plated straps and nuts. Clamps shall have rubber gasket cemented to the body.

2.19 TAPPING SLEEVES Tapping sleeves of the sizes indicated for connection to existing main shall be the cast gray, ductile, or malleable iron, split-sleeve type with flanged or grooved outlet, and with bolts, follower rings and gaskets on each end of the sleeve. Construction shall be suitable for a maximum working pressure of 150 psi. Bolts shall have square heads and hexagonal nuts. Longitudinal gaskets, and mechanical joints with gaskets shall be as recommended by the manufacturer of the sleeve. When using grooved mechanical tee, it shall consist of an upper housing with full locating collar for rigid positioning which engages a machine-cut hole in the pipe, encasing an elastomeric gasket which conforms to the pipe outside diameter around the hole and a lower housing with positioning lugs, secured together during assembly by nuts and bolts as specified, pretorqued to 50 pound feet.

2.20 PIPE SLIDE PLATES Pipe slide plates shall be graphite, polytetrafluoroethylene (PTFE) Teflon, or other acceptable material. Minimum thickness shall be 1/2 inch. Maximum coefficient of friction shall be 0.09 at 500 psi. Operating temperature range shall be from below -50 degrees F to above 300 degrees F. Plates shall not require lubrication. The plates shall not be affected by high humidity or mildly corrosive atmosphere. The sliding surfaces shall be protected from accumulation of dirt and other foreign matter.

PART 3 EXECUTION 3.1 INSTALLATION Piping shall be installed as indicated on the drawings. Piping in manholes is shown in general configuration. Dimensions and lengths may vary slightly depending on pipe and fitting dimensions, location of supports and anchors, and fabrication. It shall be the Contractor's responsibility to insure that the final piping arrangement fits and conforms to the general configuration shown on the drawings. Pipe shall be cut accurately to measurements established at the site by the Contractor and shall be worked into place without springing or forcing. Care shall be taken not to weaken structural portions of the utilidor or manholes. Changes in pipe sizes shall be made with reducing fittings. Use of long screws and bushings will not be permitted. Tapping into existing systems shall be accomplished with as little system down time as possible. The Contractor shall submit his plan of action for tapping into existing systems for each tap.

3.2 HANDLING Pipe and accessories shall be handled so as to insure delivery to the utilidor in sound, undamaged condition. Particular care shall be taken not to injure the pipe coating or lining. If the coating or lining of any pipe or fitting is damaged, the repair shall be made by the Contractor at his expense in a satisfactory manner. No other pipe or material of any kind shall be placed inside a pipe or fitting after the coating has been applied. Pipe shall be carried into position and not dragged. Use of pinch bars and tongs for aligning or turning pipe will be permitted only on the bare ends of the pipe. The interior of pipe and accessories shall be

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thoroughly cleaned of foreign matter before being lowered into the utilidor and shall be kept clean during laying operations by plugging or other acceptable method. Before installation, the pipe shall be inspected for defects. Material found to be defective before or after laying shall be replaced with sound material without additional expense to the Government. Rubber gaskets that are not to be installed immediately shall be stored in a cool and dark place. Storage facilities shall be classified and marked in accordance with NFPA 704, with classification as indicated in NFPA 49 and NFPA 325-1.

3.3 CUTTING OF PIPE Cutting of pipe shall be done in a neat and workmanlike manner without damage to the pipe. Unless otherwise recommended by the manufacturer and authorized by the Contracting Officer, cutting shall be done with a mechanical type cutter. Wheel cutter shall be used when practicable. Squeeze type mechanical cutters shall not be used for ductile iron.

3.4 PIPE HANGERS, INSERTS AND SUPPORTS Pipe hangers, inserts and supports for pipe over l inch in size shall conform to MSS SP-58 and MSS SP-69. Supports shall be slotted to prevent the accumulation of liquid where water lines and sewer lines are placed on the same support. Hangers, inserts and supports shall be adequate to support the fully charged pipe in service. The maximum spacing between pipe supports for straight runs shall be as follows unless a lesser amount is recommended by the pipe and/or coupling manufacturer. The Contractor shall submit design calculations showing the adequacy of the pipe support system.

___________________________________________________________________________ Nominal Pipe Size, 1/2 and inches to 1 1 1/4 1 1/2 2 2 1/2 3 3 1/2 4 5 6 8 10 12 overMax. Span Feet 7 8 9 10 11 12 13 14 16 17 19 22 23 ____________________________________________________________________________ Nominal Tubing Size, Inches 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4 or overMax. Span Feet 5 6 6 7 8 9 10 11 12 Pipe hangers and supports shall be spaced not over 5 feet apart at heavy fittings and valves. Pipe shall be supported near each coupling and at multiple fittings as required. A hanger shall be installed not over 1 foot from each change in direction of piping. Hangers and turnbuckles for piping shall be Type 6, 9, 11, 13, or 15. Brackets for support for piping hangers shall be Type 34. Hangers for pipe 1-inch in size and smaller shall be steel straps. Straight runs over 15 feet of pipes supported on beams or brackets shall be provided with a graphite or polytetrafluoroethylene (PTFE) slide plate and/or cradle having a minimum thickness of 1/2 inch. No hangers or supports shall be suspended from manhole or utilidor tops, except as shown on the drawings. Pipes shall be supported near each coupling or joint to prevent vertical deflection of the coupling or joint, as recommended by the pipe manufacturer. Pipes shall be secured to each horizontal support in utilidors to limit side-to-side and vertical movement but not axial movement (U-bolts or equal shall be used).

33 17 11 - 12 25 January 2008


Supports in utilidors and manholes that rest on the utilidor or manhole bottom shall be protected with two coats of coal-tar coating for the bottom 6 inches of the support. Vertical piping shall be Type 8.

3.5 JOINT DEFLECTION The maximum allowable deflection will be as given in Table I at the end of this section, unless a lesser amount is recommended by the manufacturer. If the alinement requires deflection in excess of the above limitations, special bends or a sufficient number of shorter lengths of pipe shall be furnished to provide angular deflections within the limit set forth. Under no circumstances shall pipes or fittings be forced into position, with or without heat.

3.6 PLACING AND LAYING Pipe and accessories shall be carefully lowered into the utilidor by means of derrick, ropes, belt slings, or other authorized equipment. Under no circumstances shall any of the waterline materials be dropped or dumped into the utilidor. Care shall be taken to avoid abrasion of the pipe coating. When work is not in progress, open ends of pipe, fittings, and valves shall be securely closed so that no water, earth or other substance will enter the pipes or fittings. Where any part of the coating or lining is damaged, the repair shall be made by the Contractor at his expense in a satisfactory manner. Pipe ends left for future connections shall be valved, plugged or capped, and anchored, as shown.

3.6.1 Connections Where connections are made between new work and existing mains, the connections shall be made by using specials and fittings to suit the actual conditions. Standard methods are available for making connections to various types of pipe, either under pressure or in the dewatered condition. Where made under pressure, these connections shall be installed as required by the Contracting Officer.

3.7 JOINTING Sleeve type couplings shall not be used on fire lines.

3.7.1 Ductile-Iron Pipe Split sleeve joints shall be installed in accordance with AWWA C606 for grooved and shouldered pipe. Sleeve type couplings shall be installed in accordance with the manufacturer's recommendations. Mechanical and restrained push-on joints shall be installed in accordance with the applicable portions of AWWA C600.

3.7.2 Connections Connections between different types of pipe and accessories shall be made with transition fittings as required.

3.8 SERVICE LINES Services lines shall include the pipeline connecting water distribution lines to the connections with the building service as shown on the drawings. Where building services are not installed, the Contractor shall terminate the service lines inside the appropriate manhole on the main

33 17 11 - 13 25 January 2008


utilidor. Such service lines shall be closed with plugs or caps. Service lines shall be connected to the main by a rigid connection and shall have a gate valve.

3.9 FIELD COATING AND LINING OF PIPE 3.9.1 Pipe 4 Inches and Larger 3.9.1.1 Cement-Mortar Coating and Lining Field jointing shall conform to Appendix, AWWA C205. Any defective area found in the coating and/or lining of pipe and joints shall be removed to the pipe wall, and the area shall be repaired in a manner such that the repaired areas will be at least equal in thickness to the minimum coating and/or lining required for the pipe. Steel reinforcement in the coating shall be repaired or replaced as necessary to assure a complete and soundly reinforced coating.

3.10 SETTING OF FIRE HYDRANTS 3.10.1 Fire Hydrants Fire hydrants shall be located and installed as shown. Each hydrant shall be connected to the main with a 6-inch branch line. This branch shall contain one gate valve. Hydrants shall be set plumb with pumper nozzle facing the roadway and with the center of the lowest outlet between 15 inches and 20 inches above the finished surrounding grade and the operating nut not more than 48 inches above the finished surrounding grade.

3.10.2 Hydrants, After Delivery Hydrants, after delivery, shall be drained to prevent freezing and shall have the interior cleaned of all foreign matter before installation. Stuffing boxes shall be tightened and the hydrant shall be fully opened and fully closed to insure that all parts are in working condition.

3.11 CHECK VALVES AND VACUUM AND AIR RELIEF VALVES Check valves and vacuum and air relief valves shall be installed in manholes as shown.

3.12 TEES, CROSSES, AND WYES Tees, crosses and wyes for future connections shall be installed as shown.

3.13 THRUST RESTRAINT

Plugs, caps, tees and bends on all waterlines 4 inches in diameter or larger, and on fire hydrants, shall be provided with structural steel thrust blocking, anchors or metal tie rods and clamps or lugs, as shown on the drawings. Valves shall be securely anchored or shall be provided with thrust blocking to prevent movement. Blocking shall be placed between solid surface and the hydrant, valve, or fitting to be anchored. Blocking shall be placed so that the fitting joints will be accessible for repair. The connection between the utilidor water or fire lines and the interior building water or sprinkler piping, and all bends, plugs and tees on fire protection lines, shall be installed and restrained against thrust in accordance with NFPA 24, and as shown on the drawings. Steel rods and clamps shall be protected by coating with asphalt varnish or by galvanizing.

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3.14 EXPANSION

Expansion in water lines and fire lines shall be provided by bellows type expansion joints, or by grooved pipe type couplings or other pipe joints, that permit 4-inches minimum of pipe movement, or movement as noted on the drawings if larger than 4 inches. Expansion joints shall be designed for a minimum working pressure of 150 psi. Installation shall be per manufacturer's installation instructions. The length of the piping section where the expansion joint is to be installed shall be adjusted for the temperature of the pipe at the time of installation. The Contractor shall submit a table showing, for each 10 degrees F above and below the design temperature of 60 degrees F, the amount the center-to-end dimension of the joint shall be decreased or increased per each 100 feet of pipe length in the run (joint at mid-length when temperature of pipe section is 60 degrees F).

3.14.1 Bellows Type Joints Bellows type joints shall not be used with pipe joints or couplings that allow axial movement. Joints shall be packless and flexible with no internal sleeves. Expansion elements shall be of stainless steel. Bellows type expansion joints shall be in accordance with the applicable requirements of MS MIL-E-17813. Joints shall be equipped with limit rods to prevent the expansion joint from exceeding the rated travel.

3.14.2 Grooved Pipe Type Coupling Expansion Joints Joints shall be flexible. Expansion joints shall be combinations of couplings and short nipples, joined in tandem to provide increased expansion. Joints and nipples shall conform to applicable requirements of Paragraphs Fittings and Specials, and Couplings. Expansion joints shall be installed as recommended by the manufacturer.

3.14.3 Restrained Push-On Joints Flexible joints shall be installed as recommended by the pipe manufacturer to allow for axial movement within the joint due to thermal expansion and contraction.

3.15 ALIGNMENT GUIDES 3.15.1 General Alignment guides shall be cast-iron or steel and shall be so constructed that the axial movement of the pipe caused by thermal expansion will be guided in a straight line only and movement in any other direction will be adequately restrained. The guide may be a guiding cylinder attached to an anchor base or a clamp type attached to a flanged slide, moveable in guide bars attached to an anchor base. Guiding surfaces shall be machine finished and properly lubricated. The anchor base shall be correctly designed, adequately supported, and properly aligned to prevent distortion and binding of the pipe in the guide. The upper half of the clamp or guiding cylinder must be removable. All types must be designed for a pipe movement of not less than 12 inches. Guides shall be securely anchored against pipe movement. In no case will pipe rollers, racks, or hangers be considered substitutes for guides. Alignment guides that are supported from the floor of manholes or utilidors shall have the bottom 6 inches protected with two coats of coal-tar coating.

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3.15.2 At Expansion Joints Where a pipeline approaches an expansion joint, the pipeline shall be adequately guided to the joint as indicated in the following table:

ALIGNMENT GUIDE SPACING IN MANH0LES AND UTILIDORS Nominal Distance from Body Centerline of Pipe Expansion Joint to Centerline of Size 1st Alignment Guide 2nd Alignment Guide 1 to 1 1/2 inches 5 inches + 1 inch 1 foot - 6 inches + 3 inches 2 to 3 inches 10 inches + 2 inches 2 feet - 11 inches + 4 inches 4 to 8 inches 2 feet + 3 inches 7 feet - 0 inches + 5 inches 10 to 12 inches 3 feet - 8 inches + 4 inches 12 feet - 10 inches + 8 inches

3.16 ANCHORS Pipe anchors in manholes and utilidors shall be of welded construction as shown, scheduled, and detailed on the drawings. No supports, anchors, or stays shall be attached in places where they will injure the construction whether in installing or by the weight or expansion of the pipe. Any variation of the anchor design from that detailed on the drawings must have written approval of the Contracting Officer or his representative before installation. All steel shapes shall conform to ASTM A 36. Bolts and nuts shall conform to FS FF-B-575 and FS FF-N-836, as applicable. The type and class shall be the Contractor's option. For finishing, see SECTION 33 60 02 UTILID0R SYSTEM, Paragraph: PAINTING AND FINISHING. Additionally, any anchor that is supported from the manhole or utilidor bottom shall have the lower 6 inches of the anchor protected with two layers of coal-tar coating. Anchors shall be attached to pipes by welding.

3.17 INSULATION

3.17.1 General Requirements Cold water lines, including valves and fittings, throughout utilidors shall be covered with insulation. As a part of the installation, the insulation shall have the joints buttered with mastic in such a manner as to fill all insulation joints and to prevent any future passage of vapor to the cold water pipe after the assembly is complete. Special care shall be exercised to insure that joint sealer material does not drip on the utilidor floor or become smeared on the outer surface of the insulation or adjacent piping. The insulation shall be adequately secured to the pipe with 3/4-inch lacquered steel or other rust-resistant type bands, placed not over 12 inches on centers. Protection sleeves shall be provided at each support to protect the insulation. Sleeves shall be made up from a 12-inch wide strip of 20-gage galvanized sheet metal cut to provide a one-inch minimum overlap. Sleeves shall be secured to the insulation by 2 bands located approximately 1-1/2 inches from each end of the sleeve. Bands shall be the

33 17 11 - 16 25 January 2008


same type as used to secure insulation to pipe. 3.17.2 Cellular Glass Insulation Cellular glass insulation shall be 1-1/2 inches thick. Joints or fittings requiring routing out of more than 1/2 inch of insulation, to secure proper insulation fit, shall be covered with oversize insulation of sufficient thickness to obtain a minimum thickness of 1-1/2 inches. New cellular glass insulation shall be protected by a layer of glass cloth and an application of mastic asphalt to prevent physical damage. The mastic asphalt shall be fibrated asphalt, cutback with naptha solvent with at least 40 percent solids. It shall cure to form a tough film resistant to acids, alkalies, water, and shall have a low vapor permeability. It shall be sprayed or brushed on to give a coverage of not less than 10 mils.

3.17.3 Optional Use Optional Use of Polyurethane, Extruded Polystyrene, or Isocyanurate Pipe Insulation. Polyurethane, extruded polystyrene, or isocyanurate pipe insulation may be used in lieu of the cellular glass described above, at the Contractor's option. Thickness shall be as required to provide an insulating value equivalent to the thickness specified for cellular glass above, and shall be at least 3/4-inch thick. Application shall be as described in General Requirements except that a positive vapor barrier shall be provided on the outside surface of all optional use insulation including that protected by an aluminum jacket. The vapor barrier shall consist of a layer of glass cloth. The fabric shall be coated with latex paint. It shall be sprayed or brushed on to give a minimum coverage of 10 mils. In lieu of this coating, the Contractor may use a coating conforming to SECTION 33 60 02 UTILID0R SYSTEM, Extended Urethane Industrial Membrane. The waterproofing shall be applied according to the manufacturer's recommendations. All materials shall be compatible. Joints or fittings requiring routing out of more than 1/4 inch of insulation to secure proper insulation fit shall be covered with oversize insulation of sufficient thickness to obtain a minimum thickness of 3/4 inch.

3.17.4 Aluminum-Jacket Aluminum-jacket shall be provided over insulation on cold water lines in the manholes and to a distance of 5 feet into the new utilidors including valves and fittings. Aluminum-jacket material shall be of the best grade suitable for service. Aluminum-jackets shall be not less than 0.016-inch thick and shall be secured with aluminum bands not less than 318-inch wide and not more than 8 inches apart. Jacket sections shall have 1-inch hem turned along one longitudinal edge and shall be applied with the hemmed edge over the unhemmed edge. The longitudinal and circumferential seams shall be lapped not less than 2 inches. Jackets on horizontal lines shall be installed so that the longitudinal seams are on the bottom side of the pipe with the seam of each jacket slightly offset from the seam of the adjacent jackets. The seams of jackets installed on vertical lines shall be slightly offset as on horizontal lines. The jackets on vertical lines and lines pitched from the horizontal shall be installed from low point to high point so that the lower circumferential edge of each jacket overlaps the jacket below it. Special fitting jackets conforming to the above, with the exception of longitudinal lapping dimensions and location of seams, may be used for fittings, valves, and flanges. Jackets for fittings, valves, and flanges shall be properly overlapped and secured. Under no conditions

33 17 11 - 17 25 January 2008


shall the jacketing be allowed to become electrically coupled to the piping or be installed vapor tight.

3.17.5 Proposals for the Use of Substitute Materials and Methods The Contractor may propose the use of insulation materials and methods of installation other than those specified above. The Contractor will be authorized to use such substitute materials and methods provided they have been approved in writing by the Contracting Officer prior to installation. Approval of proposals for use of substitute materials and methods will be given only if sufficient evidence is presented, with the request for their use, to demonstrate their durability and functional adequacy in every respect. Approval will not be granted for use of any substitute materials or methods which permit the permeation of water vapor into or through the insulation or through the insulation joints, or which will not withstand 200 degrees F minimum temperature without damage. Any approval of substitute materials and methods will be made contingent on an equitable adjustment in contract price; and the Contractor shall furnish, along with any proposal, a detailed estimate showing the difference in cost between his proposal and the materials and methods delineated in the plans and specifications.

3.18 HYDROSTATIC TESTS Where any section of a water line is provided with concrete thrust blocking for fittings or hydrants, the hydrostatic tests shall not be made until at least 5 days after installation of the concrete thrust blocking unless otherwise approved. The method proposed for disposal of waste water from hydrostatic tests and disinfection shall be submitted to the Contracting Officer prior to performing hydrostatic tests.

3.18.1 Hydrostatic Test

After the pipe is laid, the joints completed, and the fire hydrants permanently installed, the newly laid piping or any valved section of water distribution, or water service piping, or fire line shall, unless otherwise specified, be subjected for 2 hours to a hydrostatic pressure test of 200 psi. Each valve shall be opened and closed several times during the test. Exposed pipe, joints, fittings, valves and hydrants shall be carefully examined during the test. No leakage will be allowed. Joints showing visible leakage shall be replaced or remade as necessary. Cracked or defective pipe, joints, fittings, valves, or hydrants discovered in consequence of this pressure test shall be removed and replaced with sound material, and the test shall be repeated until the test results are satisfactory.

3.18.2 Time for Making Test Except for joint material setting or where concrete thrust blocking necessitates a 5-day delay, pipelines may be subjected to hydrostatic pressure, inspected, and tested at any time after the line is secured. Cement-mortar lined pipe may be filled with water as recommended by the manufacturer before being subjected to the hydrostatic test.

3.18.3 Concurrent Hydrostatic Tests The Contractor may elect to conduct the hydrostatic tests using the following procedures. Regardless of the sequence of tests employed, the results of hydrostatic tests and disinfection shall be satisfactory as

33 17 11 - 18 25 January 2008


specified. All replacement, repair or retesting required shall be accomplished by the Contractor at no additional cost to the Government.

3.18.3.1 Hydrostatic Tests and Disinfection Hydrostatic tests and disinfection may be conducted concurrently, using the water treated for disinfection to accomplish the hydrostatic tests. If water is lost when treated for disinfection and air is admitted to the unit being tested, or if any repair procedure results in contamination of the unit, disinfection shall be reaccomplished.

3.19 DISINFECTI0N Before acceptance of potable water operation, each unit of completed water and fire line shall be disinfected as prescribed by AWWA C651. The unit will not be accepted until satisfactory results have been obtained from water samples submitted by the Contractor to a laboratory certified by the State of Alaska to perform testing for coliform bacteria.

3.20 CLEANUP Upon completion of the installation of the water distribution lines and water service lines, fire lines, and appurtenances, all debris and surplus materials resulting from the work shall be removed.

TABLE I. DEFLECTION ANGLES Split Sleeve Mechanical Diameter Split Sleeve Ductile Iron Sleeve Type Joint Ductile in Inches Steel Joint Pipe Joint Pipe Couplings Iron Pipe 3 2 deg. 3' 1 deg. 21' 4 deg. 00' 8 deg. 18' 4 3 deg. 11' 1 deg. 8' 4 deg. 00' 8 deg. 18' 6 2 deg. 10' 0 deg. 47' 4 deg. 00' 7 deg. 07' 8 1 deg. 40' 0 deg. 36' 4 deg. 00' 5 deg. 21' 10 1 deg. 20' 0 deg. 48' 4 deg. 00' 5 deg. 21' 12 1 deg. 7' 0 deg. 41' 4 deg. 00' 5 deg. 21'

-- End of Section --

33 17 11 - 19 25 January 2008


SECTION 33 31 17

SEWERS IN UTILIDORS

01/03 PART 1 GENERAL 1.1 REFERENCES The publication listed below form a part of this specification to the extent referenced. The publication are referred to in the text by basic designation only.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) ANSI B18.2.1 (1996; Errata 2003) Square and Hex Bolts

and Screws Inch Series

ASTM INTERNATIONAL (ASTM) ASTM A 123/A 123M (2002) Zinc (Hot-Dip Galvanized) Coatings

on Iron and Steel Products ASTM A 536 (1984; R 2004) Ductile Iron Castings

ASTM D 2000 (2006a) Rubber Products in Automotive Applications

AMERICAN WATER WORKS ASSOCIATION(AWWA)

AWWA C111 (2000) Rubber-Gasket Joints for

Ductile-Iron Pressure Pipe and Fittings

STATE OF ALASKA ADMINISTRATIVE CODE (AAC) 18 AAC 72 (2006) Wastewater Treatment and Disposal

1.2 GENERAL This section covers sewage lines, both gravity and force mains.

Recommendations of the Manufacturer: The Contractor shall, as a part of the shop drawings, submit to the Contracting Officer the manufacturer's recommendations for each material or procedure to be utilized which is required to be in accordance with such recommendations. The Contractor shall have a copy of the manufacturer's instructions available at the construction site at all times and shall follow these instructions unless otherwise directed by the Contracting Officer.

The Contractor shall obtain the construction certification as required by the Alaska Department of Environmental Conservation (ADEC) under 18 AAC 72.235. The Contractor's construction certification works shall include the record drawings, the observing engineer, and signing the certificate of construction form. In addition, the Contractor shall obtain any ADEC required interim permits as well as the final permit to operate the system.

33 31 17 - 1 25 January 2008



SD-02 Shop Drawings

Sewer Distribution System; G

SD-03 Product Data

Materials



SD-06 Test Reports

Hydrostatic tests; G


Manufacturer's Recommendations 1.4 SUBMITTALS SUPPLEMENTAL See paragraphs below for further descriptions of submittals required by paragraph SUBMITTALS:

1.4.1 Sewer Distribution System Detail drawing for alignment guides, anchors, expansion joints, flanges, gaskets, hangers and supports, insulation, pipe, and valves, including a complete list of equipment and material, manufacturer's descriptive and technical literature, catalog cuts, and installation instructions. Drawings shall contain complete pipe stress calculations for all expansion joints, expansion loops, and any other details required to demonstrate that the system has been coordinated and will properly function as a unit. Drawings shall show proposed system layout, provisions for expansion, pipe anchors and guides, and layout and anchorage of equipment and appurtenances in valve manholes, and equipment relationship to other parts of the work including clearances for maintenance and operation.

Any supports, anchors, guides, expansion joints, etc., for the piping system shown on the drawings are generic only. The Contractor shall be responsible for the design of the piping system and shall submit design calculations and shop drawings for the piping system. Design shall meet requirements of theses specifications including, but not limited to material size, quality, and finish. Calculations shall be stamped and signed by an engineer registered in the State of Alaska.

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1.4.1 Materials Manufacturer's descriptive data, catalog cuts, and brochures for each type and size of the following:

a. Couplings and gaskets.

b. Combination sewage air valve.

c. Pipe.

1.4.2 Calculation of Pipe Supports Calculation of pipe supports shall be submitted with support system descriptive data, see submittal in SECTION 33 60 02 UTILIDOR SYSTEM.

1.4.3 Calculation of Pipe Anchors Calculation of pipe anchors shall be submitted with anchor sizes and drawings showing location and details of anchor. At a minimum anchors shall be placed near the locations shown on the drawings, see SECTION 33 60 02 UTILIDOR SYSTEM.

1.4.4 Hydrostatic tests Submit a hydrostatic test procedure describing method including method proposed for disposal of wastewater, see SECTION 33 17 11 WATER DISTRIBUTION IN UTILIDORS.

1.4.5 Manufacturer's Recommendations Manufacturer's recommendations for each material or procedure to be utilized which is required to be in accordance with such recommendations. The Contractor shall have a copy of the manufacturer's instructions available at the construction site at all times and shall follow these instructions unless otherwise directed by the Contracting Officer.

PART 2 PRODUCTS 2.1 MATERIALS AND EQUIPMENT Products shall be in accordance with the applicable provisions of PART 2 - PRODUCTS of SECTION 33 17 11 WATER DISTRIBUTION SYSTEMS IN UTILIDORS except as modified herein.

2.1.1 Pipe Pipe 4 inches and larger shall be ductile iron pipe as specified in SECTION 33 17 11 WATER DISTRIBUTION SYSTEMS IN UTILIDORS. Pipe for sewer force main shall have a working pressure of 150 psi. Pipe for the gravity sewer line shall have a working pressure of 50 psi.

2.1.2 Expansion Joints Expansion joints in sewer force mains shall be cut grooved pipe type couplings permitting 2 inches minimum of pipe movement, or movement as noted on the drawings if larger than 2 inches. Expansion joints shall be designed for a minimum working pressure of 150 psi. Installation shall be per manufacturer's installation instructions. The length of the piping

33 31 17 - 3 25 January 2008


section where the expansion joint is to be installed shall be adjusted for the temperature of the pipe at the time of installation. The Contractor shall submit a table showing, for each 10 degrees F above or below the design temperature of 60 degrees F, the amount the center-to-end dimension of the joint shall be decreased or increased per each 100 feet of pipe length in the run (joint at mid-length when temperature of pipe section is 60 degrees F).

2.1.2.1 Cut Grooved Pipe Type Coupling Expansion Joints Joints shall be flexible. Expansion joints shall be combinations of couplings and short nipples, joined in tandem to provide increased expansion. Joints and nipples shall conform to the applicable provisions of SECTION 33 17 11 WATER DISTRIBUTION SYSTEMS IN UTILIDORS. Expansion joints shall be installed as recommended by the manufacturer.

2.1.3 Quick Disconnect Couplings Cleanout caps shall be secured in place with quick disconnect couplings. Couplings shall be split ring type with hinged, single unit housing assembly and quick disconnect toggle housing assembly, Victaulic Style 78 Snap Joint or equal.

2.1.4 Clean Out Cap Caps for the sanitary sewer clean outs shall be grooved ductile or gray cast iron disks. The caps shall be manufactured to mate with the quick disconnect couplings. At flanged fitting cleanouts use a flange adapter nipple. Cap: Victaulic part no. 60 or equal. Flanged Adapter Nipple: Victaulic part no. 41 or equal.

2.1.5 Pipe Clamp Restraining System The pipe restraining system shall consist of pipe clamps, clamping bolts and nuts, restraining rods, T-bolts, and nuts. The clamps shall be cast from ductile iron meeting or exceeding ASTM A 536, Grade 65-45-12. The clamping bolts shall meet ANSI B18.2.1 and the rods, T-bolts, and nuts shall be high strength low alloy steel per AWWA C111. Hot dip galvanize all parts per ASTM A 123/A 123M. Romac Industries Series 600 pipe restraining system or equal.

2.1.6 Valves The force main gate valve and the sump gate valves shall use the same valves as specified in SECTION 33 17 11 WATER DISTRIBUTION SYSTEMS IN UTILIDORS for their respective pipe material and diameter.

2.1.7 Portland Cement Grout Non-Shrink Portland cement grout shall be fast setting grout. Sika Set Plug, Sika Corporation or equal.

2.1.8 Pipe Water Stop The water stop on sanitary sewer pipe penetration at concrete walls shall be modular, mechanical type, consisting of inter-locking synthetic rubber links shaped to continuously fill the annular space between the pipe and the wall opening. The elastomeric element shall meet ASTM D 2000 M# BA510. Link Seal by Thunderline Corporation or equal.

33 31 17 - 4 25 January 2008


PART 3 EXECUTION 3.1 INSTALLATION REQUIREMENTS Execution shall be in accordance with the applicable provisions of PART 3 - EXECUTION of SECTION 33 17 11 WATER DISTRIBUTION SYSTEMS IN UTILIDORS, except as modified herein.

a. The sewer lines shall not be disinfected.

b. The sewer lines shall not be insulated.

c. Provide at least one clean out in each manhole. Sewers eight inches

and larger in diameter shall have Y-style clean outs. Sewers smaller than eight inches in diameter shall have saddle-style clean outs with removable hatch measuring not less than four inches by eight inches.

d. All sewer mains and laterals shall be properly anchored. Concrete saddles are preferred.

e. The sewer line shall have a hydrostatic pressure test of 50 psi for gravity lines and 200 psi for pressure lines.


33 31 17 - 5 25 January 2008


SECTION 33 57 12

HEAT DISTRIBUTION SYSTEMS IN UTILIDORS AND MANHOLES

01/03 PART 1 GENERAL 1.1 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 designations only.


ASTM A 106 (2002; Rev. A) Seamless Carbon Steel Pipe

for High-Temperature Service ASTM A 123/A 123M (2002) Zinc (Hot-Dip Galvanized) Coatings

on Iron and Steel Products ASTM A 193/A 193M (2006a) Alloy-Steel and Stainless Steel

Bolting Materials for High-Temperature Service

ASTM A 194/A 194M (2005) Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service or Both

ASTM A 234/A 234M (2006a) Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM A 36/A 36M (2005) Carbon Structural Steel ASTM A 47/A 47M (1999; R 2004) Ferritic Malleable Iron

Castings ASTM A 53/A 53M (2006a) Pipe, Steel, Black and Hot-Dipped,

Zinc-Coated, Welded and Seamless ASTM A 733 (2003) Welded and Seamless Carbon Steel

and Austenitic Stainless Steel Pipe Nipples ASTM B 209 (2006) Aluminum and Aluminum-Alloy Sheet

and Plate ASTM C 533 (2004) Calcium Silicate Block and Pipe

Thermal Insulation ASTM C 547 (2006) Standard Specification for Mineral

Fiber Pipe Insulation ASTM C 552 (2003) Cellular Glass Thermal Insulation

33 57 12 - 1 25 January 2008


ASTM C 920 (2005) Elastomeric Joint Sealants ASTM F 1139 (1988; R 1998) Standard Specification for

Steam Traps and Drains

ASME INTERNATIONAL (ASME)

ASME B40.1 (1991) Gauges - Pressure Indicating Dial

Type - Elastic Element ASME B16.11 (2005) Forged Fittings, Socket-Welding and

Threaded ASME B16.3 (1998) Malleable Iron Threaded Fittings

ASME B16.34 (2004) Valves - Flanged, Threaded and Welding End

ASME B16.39 (1998) Malleable Iron Threaded Pipe

Unions, Classes 150, 250 and 300

ASME B16.5 (2003) Pipe Flanges and Flanged Fittings, NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B16.9 (2003) Factory-Made Wrought Steel

Buttwelding Fittings ASME B31.1 (2004; Addenda 2005) Power Piping ASME B1.20.1 (1983; R 2001) Pipe Threads, General

Purpose, Inch

EXPANSION JOINT MANUFACTURERS ASSOCIATION (EJMA) EJMA Stds (2003) EJMA Standards


MSS SP-25 (1998) Standard Marking System for Valves,

Fittings, Flanges and Unions MSS SP-45 (1998) Bypass and Drain Connection Standard MSS SP-58 (2002) Pipe Hangers and Supports -


Selection and Application MSS SP-80 (2003) Bronze Gate, Globe, Angle and Check

Valves

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) NFPA 70 (2005; TIA 2005) National Electrical Code

33 57 12 - 2 25 January 2008


THE SOCIETY FOR PROTECTIVE COATINGS (SSPC) SSPC SP 10 (1994; R 1995) Near-White Blast Cleaning

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Heat Distribution System; G

SD-03 Product Data

Spare Parts

SD-04 Samples

Insulation

SD-05 Design Data



SD-06 Test Reports

Tests

Performance test reports in booklet form showing all field tests performed to adjust each component and all field tests performed to prove compliance with the specified performance criteria, upon completion and testing of the installed system. Each test report shall indicate the final position of controls and valves.

SD-07 Certificates

Flange Gasket Kits

Certificate from the material supplier of the electrically insulating flange gasket kits stating that the supplied material meets specified requirements and that provides evidence that satisfactory operating requirements have been met, before the materials are delivered. Certificate shall be signed by an official authorized to certify in behalf of material supplier or product manufacturer and shall identify quantity and date or dates of shipment or delivery to which the certificates apply.

SD-10 Operation and Maintenance Data

Steam Distribution System; G

Six copies of operation and six copies of maintenance manuals for the equipment furnished. One complete set, prior to performance

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testing and the remainder upon acceptance. Manuals shall be provided prior to the field training course.

1.3 SUBMITTALS SUPPLEMENTAL See paragraphs below for further descriptions of submittals required by paragraph SUBMITTALS:

1.3.1 Heat Distribution System Detail drawings for alignment guides, anchors, expansion joints, flanges, gaskets, hangers and supports, insulation, pipe, pressure gauges, steam traps, sump pumps, thermometers, and valves, including a complete list of equipment and material, including manufacturer's descriptive and technical literature, performance charts and curves, catalog cuts, and installation instructions. Drawings shall contain complete wiring and schematic diagrams, pipe stress calculations for any revised expansion joints or expansion loops, and any other details required to demonstrate that the system has been coordinated and will properly function as a unit. Drawings shall show proposed system layout, provisions for expansion, pipe anchors and guides, and layout and anchorage of equipment and appurtenances in valve manholes, and equipment relationship to other parts of the work including clearances for maintenance and operation.

Any anchors, guides, expansion joints, etc., for the piping system shown on the drawings are generic only. The Contractor shall be responsible for the design of the piping system and shall submit design calculations and shop drawings for the piping system. Design shall meet requirements of these specifications including, but not limited to material size, quality, and finish. Calculations shall be stamped and signed by an engineer registered in the State of Alaska.

1.3.2 Spare Parts Spare parts data for each different item of material and equipment specified, after approval of the related submittals and not later than the start of the field tests. The data shall include a complete list of parts and supplies and source of supply.

1.3.3 Insulation Display sample sections for insulation of pipe, elbow, tee, valve, support point, and terminating points. After approval of material and prior to insulation of piping, a display shall be prepared of insulated sections showing compliance with specifications, including showing fastening, sealing, jacketing, straps, waterproofing, supports, hangers, anchors, and saddles. Display sample sections shall remain on display at the jobsite during the construction period until no longer needed.

1.3.4 Calculation of Pipe Supports Calculation of pipe supports shall be submitted with support system descriptive data.

1.3.5 Calculation of Pipe Anchors Calculation of pipe anchors shall be submitted with anchor sizes and drawings showing location and details of anchor.

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1.4 DELIVERY AND STORAGE All materials and equipment delivered and placed in storage shall be stored with protection from the weather; excessive humidity and excessive temperature variation; and dirt, dust, or other contaminants.

1.5 FIELD MEASUREMENTS The Contractor shall become familiar with all details of the work, verify all dimensions in the field, and shall advise the Contracting Officer of any discrepancy before performing the work.

1.6 OPERATION AND MAINTENANCE MANUALS 1.6.1 Steam Distribution System Operation manuals shall detail the step-by-step procedures required for system start up, operation, and shutdown. Operation manuals shall include the manufacturer's name, model number, parts list, and brief description of all equipment and their basic operating features. Maintenance manuals shall list routine maintenance procedures, possible breakdowns and repairs, and troubleshooting guides. Maintenance manuals shall include piping and equipment layout and simplified wiring and control diagrams indicating location of electrical components with terminals designated for wiring, as installed.

PART 2 PRODUCTS 2.1 GENERAL MATERIALS AND EQUIPMENT REQUIREMENTS 2.1.1 Standard Products Materials and equipment shall be the standard products of a manufacturer regularly engaged in the manufacture of such products and shall essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Equipment shall be supported by a service organization that is, in the opinion of the Contracting Officer, reasonably convenient to the site.

2.1.2 Nameplates Each major item of equipment such as sump pumps, motors, steam traps, and pressure reducing valves shall have the manufacturer's name, address, type or style, model or serial number, and catalog number on a plate secured to the item of equipment.

2.1.3 Asbestos Prohibition Asbestos and asbestos-containing products shall not be used.

2.1.4 Electrical Work Motors, manual or automatic motor control equipment, and protective or signal devices required for the operation specified shall be provided under this section in accordance with NFPA 70 and SECTION 33 71 02.00 20 UNDERGROUND TRANSMISSION AND DISTRIBUTION.

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2.2 PIPING AND FITTINGS Unless otherwise specified, all pipe, fittings, valves, and piping accessories shall conform to the requirements of ASME B31.1, and shall be the proper type, class, and grade for pressure and temperature of the heating medium.

2.2.1 Steel Pipe Steel pipe 2 inches in diameter and larger shall be seamless or electric-resistance welded conforming to ASTM A 53/A 53M, Grade B, Type E or S; or to ASTM A 106, Grade B. Steel pipe 1-1/2 inches in diameter and smaller shall be seamless conforming to ASTM A 106, Grade B. All condensate piping, gauge piping, and glycol piping 2 inch in diameter and smaller shall be schedule 80. Steam piping shall be Schedule 40. All other pipe including steam piping, shall be schedule 40. Standard and Extra Strong schedule pipes shall not be considered an alternative to schedule 40 and 80 pipes.

2.2.1.1 Nipples Nipples shall conform to ASTM A 733, schedule 40 or schedule 80, as required to match adjacent piping. Close nipples are not allowed. All condensate nipples shall be schedule 80.

2.2.1.2 Steel Flanges

Steel flanges shall conform to ASME B16.5 Class 150 and 300 and shall match valves or flanged fittings on which used. Flanges shall be raised face type. Flanges shall have the manufacturer's trademark affixed in accordance with MSS SP-25 so as to permanently identify the manufacturer. Flange fasteners shall be ASTM A 193/A 193M grade B7 studs, ASTM A 194/A 194M grade H2 nuts. Bolts are not allowed.

2.2.1.3 Flange Gaskets Flange gaskets shall be metal composition, spiral wound type at steam and condensate service. Gasket materials shall be suitable for 150 psi saturated steam. Provide with centering ring. Gaskets in glycol service shall be compatible with both ethylene and propylene glycol and be spiral wound type with centering ring.

2.2.1.4 Pipe Threads Pipe threads shall conform to ASME B1.20.1. Pipe threads may be used only on pipe 3/4 inch or smaller, located in manholes.

2.2.2 Fittings Fittings shall have the manufacturer's trademark affixed in accordance with MSS SP-25 so as to permanently identify the manufacturer.

2.2.2.1 Welded Fittings Welded fittings shall conform to ASTM A 234/A 234M, butt-welded or socket-welded, schedule 40 or schedule 80, as required to match connecting piping. Butt welded fittings shall conform to ASME B16.9, and socket welded fittings shall conform to ASME B16.11. Standard and Extra Strong schedule

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fittings shall not be considered an alternative to schedule 40 and 80 fittings.

2.2.2.2 Malleable Iron Fittings Fittings shall conform to ASME B16.3, ASTM A 47/A 47M, class as required to match connecting piping.

2.2.2.3 Unions Unions shall conform to ASME B16.39, schedule 40 or schedule 80, as required to match adjacent piping.

2.2.3 Insulating Flanges and Dielectric Waterways

Insulating flanges or flange gasket kits shall be installed at every pipe connection from the utilidor system to an underground system and at dissimilar metals. The kit shall consist of a flange gasket, bolt sleeves, and one insulating washer and one steel washer for both ends of each bolt. The gasket kits shall be capable of electrically isolating the pipe at the pressure and temperature of the heating medium at the point of application. Material of the type being used must have been installed in an installation which has been satisfactorily operating for not less than 2 years. The Contractor shall ensure that these kits are provided and properly installed according to manufacturer published instructions as indicated. Dielectric waterways shall have temperature and pressure rating equal to or greater than that specified for the connecting piping and shall be used for joining dissimilar metals, 3/4 inch and smaller threaded pipe. Waterways shall have metal connections on both ends suited to match connecting piping. Dielectric waterways shall be insternally lined with an insulator specifically designed to prevent current flow between dissimilar metals. Dielectric flanges shall meet the performance requirements described herein for dielectric waterways.

2.3 VALVES

Unless otherwise specified, valves shall comply with the material, fabrication, and operating requirements of ASME B31.1. Valves shall be suitable for the temperature and pressure requirements of the system on which used. Valves 2 Inches and smaller shall be bronze. Valves 2-1/2 Inches and larger shall be steel. Valves shall have the manufacturer's trademark.

2.3.1 Steel Valves Globe, gate, angle, and check valves shall conform to the requirements of ASME B16.34 and ASME B31.1 for the temperature and pressure requirements of the system. Valves shall be Class 150, cast steel, rising stem OS&Y (Outside Screw and Yoke) with raised face flanges. Adjoining flanges at piping or piping assesories shall also be raised faced type. Valves for steam service 4 inches and larger shall have a 1 inch minimum gate or globe bypass valve sized in conformance with MSS SP-45. Valve seats shall be chrome, stellite, or stainless steel.

2.3.2 Bronze Valves 2.3.2.1 Globe, Gate, and Angle Valves Globe, gate, and angle valves shall conform to requirements of MSS SP-80.

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Valves shall be Class 300, bronze body, rising stem with threaded connections.

2.3.2.2 Check Valves Check valves shall conform to the requirements of MSS SP-80. Valves shall be Class 300, bronze body seats and disks, with threaded connections.

2.3.3 Packing Packing used with valves shall not contain asbestos. Valve stem packing shall be die-formed, ring type specifically designated as suitable for the temperature and pressure of the service and compatible with the fluid in the system. Packing rings shall be polytetrafluoroethylene with minimum 50 percent graphite filament top and bottom rings. Valves 1-1/2 inches and smaller shall have four or five packing rings and valves 2 inches and larger shall have at least six packing rings. Spiral or continuous packing will not be acceptable. A metal insert shall be provided having proper clearance around the valve stem at the bottom of the stuffing box and acting as a base for the packing material. Packing glands shall be furnished with a liner of noncorrosive material and shall be of one piece construction with provisions for not less than two bolts for packing adjustment. Valve packing in glycol service shall be as recommended for both ethylene and propylene glycol.

2.4 STEAM TRAPS

Class of trap bodies shall be suitable for a working pressure of not less than 1.5 times the steam supply pressure, but not less than 200 psi, and traps shall be capable of operation under a steam-supply pressure as indicated. Traps shall be sized for the operating load and shall have capacities as shown when operating under the specified working conditions. Traps shall fail open.

2.4.1 Thermodynamic Traps Traps shall be thermodynamic type conforming to ASTM F 1139. Traps shall have 3/4 inch inlet and outlet with integral strainers. SPIRAX SARCO TD42H, or similiar.

2.5 STRAINERS

Strainers shall be basket or Y-type with connections the same size as the pipe lines in which the connections are installed. Strainer shall be suitable for the temperature and pressure requirements of the system. The strainer bodies shall be of cast steel with bottoms drilled and plugged. The bodies shall have arrows clearly cast on the sides to indicate the direction of flow. Each strainer shall be equipped with an easily removable cover and sediment basket. The body or bottom opening shall be equipped with nipple and gate valve for blowdown. The basket shall be of not less than 0.025 inch thick stainless steel, or monel with small perforations of sufficient number to provide a net free area through the basket of at least 2.5 times that of the entering pipe. The flow shall be into the basket and out through the perforations.

2.6 PRESSURE GAUGES

Gauges shall conform to ASME B40.1 and shall be provided with a pig-tail snubber for steam lines or a pulsation dampener for condensate lines. All

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gauges shall be provided with a shut-off isolation valve. Minimum dial size shall be 4-1/4 inches.

2.7 THERMOMETERS

2.7.1 Dial Dial type thermometer shall be 3-1/2 inches in diameter chromium plated case, remote-type bulb or direct-type bulb as required, plus or minus 2 degree F accuracy, white face with black digits graduated in 2 degree F increments.

2.8 INSULATION AND JACKETING 2.8.1 Insulation for Piping in Utilidors and Valve Manholes Insulation for all piping, fittings, and valves in manholes (and extending 5 feet into the utilidors) shall be molded calcium silicate conforming to ASTM C 533, Type I, asbestos free with an aluminum jacket covering. Insulation for all piping, fittings, and valves in utilidors shall be molded calcium silicate conforming to ASTM C 533, Type I, asbestos free with an aluminum jacket covering, or molded mineral fiber/fiberglass insulation conforming to ASTM C 547, Class 2, asbestos free with a nonmetallic jacket covering, or cellular glass insulation conforming to ASTM C 552. Insulation shall be factory or field applied. Other than FOAMGLAS, laminated construction shall not be used in thicknesses less than 4 inches. Steam trap and steam trace piping shall be uninsulated, except in selected high traffic locations requiring crossing by personel which shall be insulated with molded mineral fiber insulation conforming to ASTM C 547, Class 2, asbestos free with an aluminum jacket covering.

2.8.2 Aluminum Jacket Jacket shall be smooth sheet, 0.016 inch nominal thickness; ASTM B 209, Type 3003, 3105, or 5005. Aluminum jacket shall be used over calcium silicate insulation.

2.8.3 Nonmetallic Jacket Nonmetallic jackets shall be of the AWJ (All Weather Jacket) type. Nonmetallic jacket shall consist of a 6 ounce per square yard fiberglass fabric impregnated with chlorosulfonated polyethylene (Hypalon) and a 1.5 mils polyvinyl fluoride film (Tedlar) bonded to it. Overall thickness of the composite shall be 0.010 inch and weigh approximately 10.5 ounces per square yard.

Jacket may be either field or factory applied to the insulation. Nonmetallic jacket shall be used with molded mineral fiber insulation. This jacket shall not be used with any calcium silicate insulation.

2.8.4 Bands Bands for aluminum jacket shall be 3/8 inch wide and 32 gauge thickness made of aluminum or annealed stainless steel. Bands for insulation shall be 1/2 inch wide and 32 gauge thickness made of annealed stainless steel.

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2.8.5 Insulation for Flanges, Unions, and Fittings Flanges, unions, and fittings shall be insulated with premolded prefabricated, or field fabricated segments of insulation. Insulation shall be removable and reusable and shall have essentially the same thermal characteristics and thickness as the adjoining piping.

2.8.6 Insulation for Valves and Expansion Joints Valves, flexible expansion loops, and expansion joints shall be insulated with premanufactured blankets with heavy fabric covers. Products shall be manufactured for the purpose intended here and shall be suitable for the temperatures encountered. Insulation shall be removable and reusable and shall have essentially the same thermal characteristics and thickness as the adjoining piping. Insulation shall be secured with nylon buckles and straps or with velcro straps on the outside of the insulation. Insulation secured with wire or rope lacing systems shall not be acceptable.

2.8.7 Insulation Inserts at Pipe Supports and Pipe Carriers Insulation inserts at pipe supports or carriers shall consist of pipe insulation with a vapor barrier or jacket to match the adjacent insulation system, and a steel protection saddle welded to the pipe. The interior space between the steel protection saddle and the pipe shall also be filled with insulation. The vapor barrier or jacket shall be terminated around the perimeter of the steel protection saddle. The steel protection saddle shall be in accordance with MSS SP-69, Type 39. The steel protection saddle dimensions shall be appropriate for pipe size, insulation thickness and calculated loads. The Contractor shall insulate to fill the space between the steel protection saddle and the pipe in manholes.

2.9 EXPANSION JOINTS Expansion joints shall be the packed type, Hyspan 6501 or equal. Expansion joints shall provide for either single or double slip of connected pipes, as required or indicated, and for not less than the traverse indicated. Joints shall be designed for steam working pressure not less than 150 psi and shall be in accordance with applicable requirements of EJMA Stds and ASME B31.1. End connections shall be flanged unless specified otherwise on the drawings. Joints shall be provided with anchor base where required or indicated. Joint components shall be fabricated from material equivalent to that of the pipeline. Expansion joint travels shall be as specified on the drawings. These travels were designed to compensate for the differences between an installation temperature of 50 degrees F to a potential operating temperature as indicated on the drawings. Initial preset extension or compression of the expansion joints shall be made in accordance with manufacturer's recommendations to compensate for the difference between ambient temperature at time of installation and a design installation temperature of 50 degrees F. Pipe alignment guides shall be the cylinder type with a guide spider attached to the pipe. Pipe alignment guides using a slide plate shall not be acceptable. Pipe alignment guides shall be installed as recommended by joint manufacturer, but in any case shall not be more than 5 feet from expansion joint, except that for lines 4 inches or smaller, guides shall be installed not more than 2 feet from the joint. Service outlets shall be provided where indicated. Alignment guides shall not be used as a pipe support unless specifically recommended by the manufacturer.

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2.10 CONCRETE WORK

2.10.1 Concrete Concrete shall be as specified in SECTION 03 30 04 CONCRETE FOR MINOR STRUCTURES.

2.10.2 Concrete Joint Sealants Concrete joint sealants shall conform to ASTM C 920, Type M (multicomponent), Class 25, grade NS (nonsag) for vertical surfaces or grade P (pourable selfleveling).

2.10.3 Gasket Material Gasket material used between utilidor covers and utilidor wall tops shall be as specified in SECTION 33 60 02 UTILIDOR SYSTEM.

2.10.4 Concrete Expansion Joints, Contraction Joints, and Waterstops Concrete expansion joints, contraction joints, and waterstops shall be as specified in SECTION 03 30 04 CONCRETE FOR MINOR STRUCTURES.

2.11 BITUMINOUS PAVING

Bituminous course and tack coat used at street crossings shall be as specified in SECTION 32 13 18 BASE COURSE AND BITUMINOUS PAVING FOR VEHICLE TRAFFIC AREAS.

2.12 MISCELLANEOUS METAL

Miscellaneous metal not otherwise specified shall conform to SECTION 05 50 00 METALS: MISCELLANEOUS AND SHOP FABRICATIONS. Miscellaneous metal bolted together, shop welded, or assembled in the field, and pipe supports including structural cross support members and anchors shall be hot-dip galvanized in accordance with SECTION 05 50 00 METALS: MISCELLANEOUS AND FABRICATIONS.

2.13 ACCESS HATCHES Access hatches in manholes shall be an aluminum frame and cover. Access hatches shall be 36 inch by 48 inch nominal size unless otherwise indicated.Manholes will have Bilco-style aluminum lids (J-AL, JD-AL, or approved equal) with fixed ladders. Frost lids will also have Bilco-style aluminum lids. Some lids may open at the center of the ladder in two halves, opening right and left. Some lids may open at the center of the ladder toward the back of the manhole.

2.14 FLEXIBLE EXPANSION LOOPS

Use for heating water and heating glycol solutions only, not for use with steam and condensate. Provide flexible expansion loops of size and type noted on drawings. Flexible loops shall consist of two flexible sections of hose and braid, two 90° elbows, and a 180° return assembled in such a way that the piping does not change direction, but maintains its course along a single axis. Flexible loops shall have a factory supplied, center support nut located at the bottom of the 180° return, and a drain/air release plug. Flexible loops shall impart no thrust loads to system support anchors. Flexible expansion loops to be "Metraloop" as manufactured by The Metraflex

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Company or approved equal product.

2.14.1 Ratings

Flexible expansion loops shall be rated for a minimum 225 psi at 70 degrees F for hydrostatic test purposes. Flexible loops shall be rated for a minimum of 200 psi at 200 degrees F safe working pressure.

2.14.2 End Connections

End connections shall be ANSI class 150 flanges or weld end connection. Weld end connections shall be installed such that field installed flanges in piping will allow removal of flexible expansion loop.

PART 3 EXECUTION 3.1 SITEWORK 3.1.1 Excavation, Trenching, and Backfilling Excavation, trenching, and backfilling of the utilidor systems, manholes, and relocation of interferences and modifications to existing facilities shall be as shown and in accordance with SECTION 31 00 00 EARTHWORK.

3.1.2 Removal, Replacement, or Relocation of Interferences Interferences indicated or found during construction shall be removed, replaced, or relocated. Removal, replacement, or relocation shall be as shown, or as approved by the Contracting Officer. Examples of interferences include:

a. Storm and sanitary sewers and manholes.

b. Water lines, gas lines, fire hydrants, and lawn sprinkler systems.

c. Power and communication lines, conduits, poles, and guys.

d. Fences, sidewalks, and signs.

e. Grass, shrubs, trees, and rocks.

3.1.3 Modifications to Existing Facilities Modifications to existing facilities shall be made as shown. Examples of modifications include:

a. Removal and replacement of street or parking area pavements.

b. Removal and replacement of curbs, gutters, and sidewalks.

c. Reconstruction of existing valve manholes.

d. New heat distribution piping entrances to buildings, valve

manholes, or utilidors. 3.1.4 Electric Work Any wiring required for the operation of the equipment specified, but not shown on the electrical drawings, shall be provided under this section in

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accordance with SECTION 33 71 02.00 20 UNDERGROUND ELECTRICAL DISTRIBUTION. 3.1.5 Painting The heat affected zone of field welded galvanized surfaces and other galvanized surfaces damaged during installation shall be cleaned in compliance with SSPC SP 10 and painted in accordance with the PAINTING, GENERAL section.

3.2 INSTALLATION Piping shall be installed as indicated on the drawings. Piping in manholes is shown in general configuration. Dimensions and lengths may vary slightly depending on pipe and fitting dimensions, location of supports and anchors, and fabrication. The Contractor shall ensure that the final piping arrangement fits and conforms to the general configuration shown on the drawings. Pipe shall be cut accurately to measurements established at the site by the Contractor and shall be worked into place without springing or forcing. Care shall be taken not to weaken structural portions of the utilidor or manholes.

3.3 PIPING 3.3.1 General Piping Requirements

Pipe shall be accurately cut to measurements established at the site and shall be worked into place without springing or forcing. Pipe shall clear all openings and equipment. Any cutting or other weakening of structural members to facilitate piping installation will not be permitted, without the prior approval of the Contracting Officer's representative. Burrs shall be removed from ends of pipe by reaming. Installation shall permit free expansion and contraction without damage to joints or hangers. Piping shall be installed in accordance with ASME B31.1. Joints for piping in utilidors and valve manholes shall be welded, except joints at valves and expansion joints which shall be flanged, unless otherwise indicated on the drawings. Joints at traps, strainers, and at valves 3/4 inch and smaller in steam, condensate, and drip lines, shall use unions and be threaded. Supports, anchors, or stays shall not be attached where either expansion or the weight of the pipe will cause damage to permanent construction. Noninsulated ferrous parts of the piping, piping support system, or equipment shall be hot-dip galvanized after fabrication in conformance with ASTM A 123/A 123M. The supports shall not rest in any drainage trenches in the utilidor floors.

a. Expansion of piping shall be provided for by expansion joints, by

changes in the direction of the run of pipe, or by expansion loops as indicated on the drawings.

b. Changes in direction shall not be made by bending the pipe.

c. All piping, unless otherwise indicated, shall be pitched with a

grade of not less than 1 inch in 20 feet toward drain points. The slope shall be maintained throughout the system, including through each leg of each expansion loop, each change of direction of the piping and each expansion joint.

d. Open ends of pipe lines and equipment shall be properly capped or

plugged during installation to keep dirt and other foreign matter out of the system.

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3.3.2 Welded Joints Joints between sections of pipe and between pipe and fittings shall be welded. The welding shall conform to the requirements specified in paragraph WELDING. Branch connections shall be made with welding tees and reducers at all connections of building service laterals to main distribution lines, regardless of size. Forged branch outlet fittings may be used for connection of smaller miscellaneous piping. However, no forged branch outlet fittings larger than 2 inches shall be permitted to be used for connections, even where the connection is not between a building service lateral and a main distribution line. Forged branch outlet fittings shall be flared for improved flow where attached to the run, reinforced against external strains, and designed to withstand full pipe bursting strength.

3.3.2.1 Quality Control

Welding shall only be done by certified welders/welding operators for the applicable Welding Procedure Specification (WPS). Only shielded metal arc methods shall be used. Records shall be available on fabrication site as required by ANSI/ASME Code for Pressure Piping, B31. The quality assurance, inspection, examination, and testing requirements of ANSI/ASME B31.1 and ASME Boiler and Pressure Vessel Code Section IX shall apply. 100% visual weld examination and 10% radiographic weld examination is required.

3.3.3 Flanged and Threaded Joints

Flanged and threaded joints are allowed in manholes only.

3.3.3.1 Flanged Joints Joints shall be faced true, provided with gaskets, and made perfectly square and tight. Electrically isolated flange joints shall be provided at all connections to building underground systems and between dissimilar metals.

3.3.3.2 Threaded Joints Joints shall have graphite or inert filler and oil, graphite compound, or polytetrafluoroethylene tape applied to the male threads only. Dielectric waterways shall be used at connections of dissimilar metals in 3/4 inch and smaller piping.

3.3.4 Reducing Fittings Changes in horizontal piping sizes shall be made through eccentric reducing fittings. Eccentric reducers in horizontal runs shall be installed with the straight side down for steam lines to maintain condensate drainage (unless otherwise indicated on the drawings). Eccentric reducers in horizontal runs shall be installed with the straight side up for condensate lines to maintain air venting (unless otherwise indicated on the drawings).

3.3.5 Branch Connections Branches from mains shall branch off top of mains, as indicated or as approved. Connections shall insure unrestricted circulation, elimination of air pockets, and shall permit the complete drainage of the system.

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Branch connections providing service to and from buildings shall use standard tee fittings with standard reducers as needed for connections larger than 1 inch.

3.4 PIPE HANGERS, INSERTS AND SUPPORTS 3.4.1 Pipe Supports in Utilidors and Valve Manholes Horizontal and vertical runs of pipe in utilidors and valve manholes shall be securely supported. All pipe supports including the structural cross support member shall be hot-dip galvanized in accordance with SECTION 05 50 00 METALS: MISCELLANEOUS AND FABRICATIONS.

3.4.2 Pipe Supports and Hangers Pipe inserts and supports for pipe shall conform to MSS SP-58 and MSS SP-69. Chain or flat steel strap hangers or single point supports will not be acceptable. Inserts and supports shall be adequate to support the fully charged pipe in service. Hangers and turnbuckles for piping shall be Type 6, 9, 11, 13, or 15. Brackets for support for piping hangers shall be Type 34. Hangers for pipe 1 inch in size and smaller shall be steel straps. Vertical piping shall be Type 8. As an alternative, the pipe support system may be an engineered system stamped and signed by a registered professional engineer, in accordance with SECTION 33 60 02 UTILIDOR SYSTEM.

Supports shall be designed to prevent the accumulation or provide for the drainage of liquid where water lines and sewer lines are placed on the same support. The maximum spacing between pipe supports for straight runs shall be as follows unless a lesser amount is recommended by the pipe and/or coupling manufacturer. The Contractor shall submit design calculations showing the adequacy of the pipe support system.

Nominal Pipe Size (inches), 1/2 12 to 1 1-1/4 1-1/2 2 2-1/2 3 4 6 8 10 and over Max. Span Feet 7 7 9 10 10 10 10 10 10 20 20 Nominal Tubing Size, 4 and Inches 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 over Max. Span Feet 5 5 6 7 8 8 9 10 10 Pipe supports shall be spaced not over 5 feet apart at heavy fittings and valves. Pipe shall be supported near each coupling and at multiple fittings as required. A support shall be installed not over 1 foot from each change in direction of piping. Straight runs of pipe over 15 feet supported on beams or brackets shall be provided with a cylinder type alignment guide with a guide spider attached to the pipe. No hangers or supports shall be suspended from removable manhole tops or removable utilidor lids. Pipes shall be supported near each coupling or joint to prevent vertical deflection of the coupling or joint, as recommended by the pipe manufacturer. Pipes shall be secured to each horizontal support in

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utilidors to limit side-to-side and vertical movement but not axial movement (U-bolts or equal shall be used). All pipe hangers and supports shall be hot-dip galvanized after fabrication to provide a Coating Grade of 65 (average zinc coating of 1.5 ounces/square foot) in accordance with ASTM A 123/A 123M.

3.4.3 Pipe Racks For pipe racks, 1-5/8 inch wide continuous slotted channels (Unistrut, or equal) shall be used, in accordance with SECTION 33 60 02 UTILIDOR SYSTEM. As an alternative, the pipe support system may be an engineered system stamped and signed by a registered professional engineer, in accordance with SECTION 33 60 02 UTILIDOR SYSTEM.

3.5 WELDING Welding and radiographic examination of all steel carrier pipe welds shall be as specified in SECTION 43 02 00 WELDING PRESSURE PIPING.

3.6 RADIOGRAPHIC TESTING Radiographic examination of field welds in the steel carrier piping of the heat distribution system shall be in accordance with ASME B31.1 performed as specified in SECTION 43 02 00 WELDING PRESSURE PIPING. An approved independent testing firm or firms regularly engaged in radiographic testing shall perform the radiographic examination of field welds in the steel carrier piping of the heat distribution system in accordance with ASME B31.1. The Contractor shall furnish a set of films showing each weld inspected, a reading report evaluating the quality of each weld, and a location plan showing the physical location where each weld is to be found in the completed project, prior to backfilling and hydrostatic testing. All radiographs shall be reviewed and interpreted by a Certified Level III Radiographer employed by the testing firm whose signature shall appear on the reading report. The Contracting Officer reserves the right to review all inspection records, and if any welds inspected are found unacceptable they will be removed, rewelded, and radiographically examined at no cost to the Government.

3.7 INSULATION The insulation shall be installed in such a manner that it will not be damaged by pipe expansion or contraction. Insulation installed over welds shall be grooved to assure a snug fit. Where, applicable, insulation shall be held in place with aluminum jackets and stainless steel straps. A minimum of 2 bands shall be installed on each individual length of insulation and maximum spacing shall not exceed 18 inch centers.

3.7.1 Installation Material shall be installed in accordance with published installation instructions of the manufacturer. Insulation materials shall not be applied until piping tests are completed.

3.7.1.1 Preparation Prior to application, surfaces shall be thoroughly cleaned of moisture, grease, dirt, rust, and scale. Insulation manufacturer's published installation instructions shall be followed.

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3.7.1.2 Thickness The minimum thickness of insulation for the heat distribution system and condensate return system shall be in accordance with Tables 1 and 2. The insulation thickness, where required, for steam trap and steam trace piping shall be 1/2 inch.

TABLE 1 Minimum Pipe Insulation Thickness (inches) _____________________________________________ For steam piping 16 psig to 250 psig and high temperature hot water supply and return piping up to 450 degrees F _______________________________________________________ Nominal Pipe Insulation Thermal Conductivity (k) Diameter _____________________________________ (in.) k less than 0.29 k from 0.29 to 0.40 k greater than 0.40 _____________ _________ _________ _________ 1.0 1.0 1.0 1.0 1.5 1.0 1.0 1.0 2.0 1.0 1.0 1.5 2.5 1.0 1.0 1.5 3.0 1.0 1.5 1.5 4.0 1.0 1.5 1.5 5.0 1.5 1.5 2.0 6.0 1.5 2.0 2.0 8.0 1.5 2.0 2.0 10.0 2.0 2.0 2.5 12.0 2.0 2.5 2.5 NOTE: Insulation thermal conductivity (k-value) is in units of Btu-inches/hour-square feet-degrees F at 200 degrees F mean temperature. TABLE 2 Minimum Pipe Insulation Thickness (inches) _____________________________________________ (For low pressure (less than 16 psig) steam, condensate return, and low temperature (less than 250 degrees F) hot water supply and return piping.) ________________________________________________________ Nominal Pipe Insulation Thermal Conductivity (k) Diameter __________________________________ (in.) k less than 0.29 k from 0.29 to 0.40 k greater than 0.40 _____________ ________ _______ _________ 1.0 0.5 0.5 0.5 1.25 0.5 0.5 0.5 1.5 0.5 0.5 0.5 2.0 0.5 0.5 0.5 2.5 0.5 0.5 1.0 3.0 0.5 1.0 1.0 4.0 1.0 1.0 1.0

33 57 12 - 17 25 January 2008


TABLE 2 Minimum Pipe Insulation Thickness (inches) _____________________________________________ (For low pressure (less than 16 psig) steam, condensate return, and low temperature (less than 250 degrees F) hot water supply and return piping.) ________________________________________________________ Nominal Pipe Insulation Thermal Conductivity (k) Diameter __________________________________ (in.) k less than 0.29 k from 0.29 to 0.40 k greater than 0.40 _____________ ________ _______ _________ 5.0 1.5 1.5 1.5 6.0 1.5 1.5 2.0 8.0 1.5 2.0 2.0 10.0 2.0 2.0 2.0 12.0 2.0 2.0 2.0

NOTE: Insulation thermal conductivity (k-value) is in units of Btu-inches/hour-square feet-degrees F at 200 degrees F mean temperature. 3.7.2 Insulation on Pipes Passing Through Sleeves Insulation shall be continuous through sleeves as shown. Aluminum jackets shall be provided over the insulation. When penetrating building or utilidor walls, the aluminum jacket shall extend not less than 2 inches beyond the sleeve on each side of the wall and shall be secured with an aluminum band on each side of the wall. Where flashing is provided, the jacket shall be secured with one band not more than 1 inch from the end of the jacket.

3.7.3 Covering of Insulation in Utilidors and Valve Manholes The insulation for pipe, flanges, and fittings in utilidors and manholes shall be covered with aluminum or nonmetallic jackets as required for the insulation type in the paragraph INSULATION AND JACKETING.

3.8 VALVE MANHOLES AND ACCESSORIES 3.8.1 Valve Manhole Construction and Accessories The valve manholes shall be constructed of reinforced concrete conforming to SECTION 03 30 04, CONCRETE FOR MINOR STRUCTURES and in accordance with SECTION 33 60 02 UTILIDOR SYSTEM.

3.8.1.1 Piping and Equipment in Valve Manholes Piping in valve manholes shall be installed and supported as shown on the drawings. All globe, angle and gate valves shall be installed with the stems horizontal or above.

33 57 12 - 18 25 January 2008


3.9 UTILIDOR SYSTEM

3.9.1 Coordination with Existing Utilities Before beginning work in a given area, all utility information shall be field verified by surface markings made by the affected utility Owner's Representative. Contractor shall notify the Contracting Officer in advance, and receive prior approval before excavating in any areas. The actual utilidor routing may be offset or changed if approved by the Contracting Officer in order to reduce conflicts, interruptions, expedite the work, or for any other reason to the mutual benefit of the Contractor and the Government.

3.9.2 Piping Support System

Piping shall have supports as indicated. No pipes, pipe supports, or other related items shall be permitted on the floor of the utilidor system. Pipe support members spanning traversely across the tunnel shall allow a minimum of 4 inches clearance between structural member and the utilidor floor. Additional minimum clearances required from the pipe insulation surface shall be as follows: 8 inches to the utilidor floor, 6 inches to side walls, 6 inches to the utilidor cover, and 6 inches between adjoining pipes.

3.9.3 Pipe Expansion

The expansion of pipes shall be provided for by changes in the direction of the run of pipe, or by expansion joints, as indicated. Initial setting shall be made in accordance with the manufacturer's recommendations to allow for ambient temperature at time of installation. Pipe in the loops and bends shall accommodate expansion while maintaining required insulation clearance from floors, walls, tops, and other pipes to avoid crushing or breaking of insulation. Slopes of pipe and utilidor bottoms shall be maintained. Contractor shall submit pipe stress calculations for each revised expansion loop or bend based on the final actual measured lengths, or shall submit dimensions to the Contracting Officer for verification of loop and bend sizes before proceeding with that segment of work. Allowable pipe stresses shall be in accordance with ASME B31.1. Final expansion loop insulation method shall be submitted for approval to the Contracting Officer.

3.9.4 Pipe Anchors Pipe anchors in manholes and utilidors shall be of welded construction, designed by the Contractor. The number and approximate location of anchors is indicated on the contract drawings. Shop drawings indicating anchor locations and details of design, including calculations, shall be submitted for Government Approval. Shop drawing approval shall be obtained prior to placing any piping. The range of anticipated pipe temperatures, which shall be used to determine the design forces on anchors, is from 32 degrees F to a potential operating temperature as indicated on the drawings. Pressures for calculating forces are as follows: Working pressure of 150 psig and a test pressure of 200 psig. If expansion anchors are used in lieu of cast in place anchor bolts, an additional safety factor of 1.5 shall be used in sizing the anchor bolts. No supports, anchors, or stays shall be attached in places where they may cause damage during installation or by the weight or expansion of the pipe. All steel shapes shall conform to ASTM A 36/A 36M. The type and class shall be the Contractor's option. For finishing, see SECTION 33 60 02 UTILID0R SYSTEM, paragraph PAINTING AND

33 57 12 - 19 25 January 2008


FINISHING. Additionally, any anchor that is supported from the manhole or utilidor bottom shall have the lower 6 inches of the anchor protected with two layers of coal-tar coating. Anchors shall be attached to pipes by welding. Anchor bolts and nuts shall be stainless steel.

3.9.5 Pipe Alignment Guides

Provide pipe alignment guides at expansion joints and flexible expansion loops as required by manufacturer and and as indicated on plans and details. Pipe alignment guides shall be installed as recommended by the joint manufacturer, but in any case shall be not more than 5 feet from expansion joint, except in lines 4 inches or smaller where guides shall be installed not more that 2 feet from the joint.

3.10 TESTS Tests shall be conducted before, during, and after the installation of the system. All instruments, equipment, facilities, and labor required to properly conduct the tests shall be provided by the Contractor.

3.10.1 Control Valves and PRV Stations Prior to cleaning of piping and the hydro-static and operating tests, the Contractor shall install 100 mesh screens in the strainers of all control valve assemblies and PRV (pressure reducing valve) stations for all affected facilities. Facilities shall include building mechanical rooms and steam trace lines. The Contractor shall save the original existing strainer screens. The Contractor shall replace the original existing strainer screens no less than 2 months after that section of utilidor has been placed back in operation.

3.10.2 Cleaning of Piping Prior to the hydrostatic and operating tests, the interior of the piping shall be flushed with clean water until the piping is free of all foreign materials. Flushing and cleaning out of system pipe, equipment, and components shall not be considered completed until witnessed and accepted by the Contracting Officer. After flushing the system is completed, the system shall be drained and filled with clean water. Temporary strainers shall be provided for all equipment and control valves to prevent clogging in accordance with the previous paragraph.

3.10.3 Test Pressure Gauges Test pressure gauges for a specific test shall be approved by the Contracting Officer and shall have dials indicating not less than 1-1/2 times, nor more than 3 times the test pressure. All test gauges used for reading test pressures shall have been calibrated annually and traceable to a nationally recognized standard. When the test gauge is used for pressure testing no more than twelve months shall have elapsed since the last calibration. The contractor shall have documented evidence of calibration of the test pressure gauge available for review by the COR. A check gauge shall be installed on the test apparatus. The check gauge shall be installed during the pressure test and shall read within 2 psi of the test gauge. If the difference in readings exceeds 4 psi, one gauge shall be recalibrated.

33 57 12 - 20 25 January 2008


3.10.4 Field Tests The following field tests shall be conducted when applicable to the system involved. If any failures occur, the Contractor shall make such adjustments or replacements as the Contracting Officer may direct, and the tests shall be repeated until satisfactory tests are completed.

3.10.4.1 Hydrostatic Tests of Service Piping Service piping shall be tested hydrostatically before insulation is applied at field joints, and shall be proved tight at a pressure 1-1/2 times the working pressure of 150 psig or at 200 psig, whichever is greater. Hydrostatic test pressure shall not exceed 500 psig. Hydrostatic test pressures shall be held for a minimum of 4 hours. If the hydrostatic test pressure cannot be held, the Contractor shall make such adjustments or replacements and the tests repeated until satisfactory results are achieved. Expansion joints shall be restrained during hydrostatic test.

3.10.4.2 Equipment Tests All pumps, valves, traps, alarms, controls, and any other operable item of equipment shall be operated to verify proper operation and compliance with the specifications. Pump voltage, current, and discharge readings shall be recorded and submitted for approval in accordance with submittal Tests.

3.10.4.3 Insulating Flange Test Insulating flanges shall be tested for electrical isolation in accordance with the insulating flange manufacturer's standard test. This test shall be witnessed and approved by the Contracting Officer.

3.10.4.4 Operational Tests After installation of the utilidor system, or testable portion thereof, operational tests shall be conducted. The utilidor covers shall not be placed prior to completion of operational tests. Operational tests shall consist of operating the system at the pressure and temperature expected for the system when in normal service, and shall demonstrate satisfactory operating effectiveness. The test on each system, or portion thereof, shall last a minimum of 24 hours.

3.10.4.5 Utilidor Water Removal Tests After the above tests are completed, and before the utilidor and valve manhole covers are placed, the utilidors, sumps, and valve manholes shall be cleaned of dirt and debris. The utilidor system shall be tested to ensure gravity drainage of water is maintained in the utilidor bottom from high points to drained low points. Contractor shall verify water does not pond between high and low points, and that drained low points are operational either by use of sump pumps or by gravity drainage to storm drains, as indicated. Test shall not be considered completed until witnessed and accepted by the Contracting Officer. The utilidor tops shall be placed and sealed immediately after approval by the Contracting Officer.


33 57 12 - 21 25 January 2008


SECTION 33 60 02

UTILIDOR SYSTEM

08/02 PART 1 GENERAL 1.1 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.


ASTM A 36/A 36M (2005) Carbon Structural Steel

ASTM A 123/A 123M (2002) Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A 153/A 153M (2005) Zinc Coating (Hot-Dip) on Iron and

Steel Hardware

ASTM A 570 (1984) Stee, Sheet and Strip, Carbon, Hot-Rolled, Struct

ASTM A 780 (2001; R 2006) Repair of Damaged and Uncoated Areas of Hot-Dipped Galvanized Coatings

ASTM B 633 (1998; E 2001) Electrodeposited Coatings

of Zinc on Iron and Steel ASTM C 208 (1995; (R 2001) Cellulosic Fiber

Insulating Board ASTM C 501 (1984; R 1996) Relative Resistance to Wear

of Unglazed Ceramic Tile by the Taber Abraser

ASTM C 578 (2006) Rigid, Cellular Polystyrene Thermal

Insulation ASTM C 726 (2000, Rev A) Mineral Fiber Roof

Insulation Board ASTM C 920 (2005) Elastomeric Joint Sealants ASTM D 36-95 (2000)e1 Standard Test Methods for

Softening Point of Bitumen (Ring-and-Ball Apparatus)

ASTM D 1777 (1996) Measuring Thickness of Textile Materials

33 60 02 - 1 25 January 2008


ASTM D 2240 (2002) Rubber Property - Durometer Hardness ASTM D 412 (1998a; R 2002e1) Vulcanized Rubber and

Thermoplastic Elastomers - Tension ASTM D 449 (1989; R 1999el) Asphalt Used in

Dampproofing and Waterproofing ASTM D 5034 (1995) Breaking Strength and Elongation of

Textile Fabrics (Grab Test)

ASTM D 624 (2000e1) Tear Strength of Conventional Vulcanized Rubber and Thermoplastic Elastomers

ASTM D 751 (2000) Standard Test Methods for Coated Fabrics

ASTM E 96 (2005) Water Vapor Transmission of

Materials ASTM D 41 (1984; R 2000) Asphalt Primer Used in

Roofing, Dampproofing, and Waterproofing ASTM D 43 (2000) Coal Tar Primer Used in Roofing,

Dampproofing, and Waterproofing ASTM D 450 (1996; R 2000) Coal-Tar Pitch Used in

Roofing, Dampproofing and Waterproofing ASTM D 648 (2000a) Deflection Temperature of Plastics

Under Flexural Load


MSS SP-58 (2002) Pipe Hangers and Supports -


Selection and Application

THE SOCIETY FOR PROTECTIVE COATINGS (SSPC) SSPC Paint 25 (1997; E 2004) Zinc Oxide, Alkyd, Linseed

Oil Primer for Use Over Hand Cleaned Steel, Type I and Type II

U.S. ARMY CORPS OF ENGINEERS (USACE)

TI 809-04 (1998) Seismic Design for Buildings

U.S. GENERAL SERVICES ADMINISTRATION (GSA) FS TT-S-001543 (Rev. B) Sealing Compound: Silicone

Rubber Base (For Calking, Sealing, and Glazing in Buildings and Other Structures)

33 60 02 - 2 25 January 2008


FS A-A-60005 (1998) Frames, Covers, Gratings, Steps, Sump and Catch Basin, Manhole Castings

CID A-A-1632 (Basic) Varnish, Asphalt

1.2 GENERAL REQUIREMENTS 1.2.1 Winter Heating Requirement When the ambient air temperature is below 32 degrees F, the utilidor sections and manholes shall be heated. All temperatures shall be constantly and adequately monitored. The Contractor shall submit its heating and monitoring plan as detailed in paragraphs QUALITY PROVISIONS and SUBMITTALS. For the purposes of this paragraph, "backfilled" shall mean that insulation, if required, has been installed and backfill has been placed as directed by contract plans and specifications up to within 3 inches of the top of the structure's walls. This requirement shall apply to both new utilidors and manholes, and existing utilidors and manholes that have work under this contract.

a. When the utilidor sections or manholes are insulated and backfilled, the structures shall be heated such that the minimum inside air temperature at all locations is 40 degrees F.

b. When the utilidor sections or manholes are not backfilled, the entire structure, to include air spaces and all external surfaces and unbackfilled trench areas within 3 lineal feet of the structure's walls, shall be heated to 40 degrees F minimum.

c. Any utilidor system not included in this contract but connected to utilidors having work under this contract shall be heated as described above. The extent of this heating shall include all areas that are disturbed under this contract. "Disturbed" shall include excavation or any other work that alters the thermal regime and exposes the utilidor and/or manholes to freezing temperatures.

1.2.2 Nameplates Each major item of equipment shall have the manufacturer's name, address, type or style, and model or serial number on a plate secured to the item of equipment.

1.2.3 Verification of Dimensions The Contractor shall become familiar with all details of the work, verify all dimensions in the field, and shall advise the Contracting Officer of any discrepancy before performing any work.

1.2.4 Steam, Water, and Sewerage Facilities All steam, water and sewerage facilities and all other work required to be installed in the completed utilidors as called for by the drawings or specifications shall be furnished and installed in accordance with the applicable provisions of other sections of these Specifications.

33 60 02 - 3 25 January 2008


1.2.5 Site Work 1.2.5.1 Excavation, Trenching, Filling and Backfilling Excavation, trenching, filling and backfilling shall be as here in before specified in SECTION 31 00 00 EARTHWORK of these specifications. The utilidors shall be constructed to the grades as required by the drawings.

1.2.5.2 Relocation of Interferences Interferences as indicated, or as found during construction, shall be removed or relocated as necessary. Relocations shall be as indicated or as approved by the Contracting Officer. Examples of interferences are:

a. Power and Communication lines;

b. Fences and sidewalks;

c. Utilidors.

1.2.5.3 Modifications to Existing Facilities Modifications shall be made as indicated. Examples of modifications are:

a. Removal and replacement of street or parking area pavements.

b. Re-construction of existing manholes.

c. New utility distribution piping entrances to buildings, manholes, or utilidors.

Any other modifications shall be made as required for complete installation of the utilidor system as indicated.

1.2.6 Standard Products The equipment to be furnished under this specification shall be essentially the standard product of the manufacturer. Where two or more units of the same class of equipment are required, these units shall be the products of a single manufacturer; however, the component parts of the system need not be the products of the same manufacturer. The products of any reputable manufacturer regularly engaged in the commercial production of required equipment will not be excluded on the basis of minor differences, provided all essential requirements of this specification relative to materials, capacity and performance are met.


SD-01 Preconstruction Submittals

Heating and Temperature Monitoring Plan; G

SD-02 Shop Drawings

33 60 02 - 4 25 January 2008


Detail Drawings

Fabrication and Erection Drawings

SD-03 Product Data

Schedules of Work and Tests Required for Installation

Manufacturer's Catalog Data

SD-04 Samples

Materials

SD-05 Design Data

Steel Strut Pipe Support System Design Calculations

Seismic Bracing


Waterproofing Material

1.4 SUBMITTALS SUPPLEMENTAL See paragraphs below for further descriptions (when available) of submittals required by paragraph SUBMITTALS:

1.4.1 Detail Drawings Fabrication and assembly drawings of work in sufficient detail to verify compliance with the contract for the following:

a. Sump Pumps

b. Precast or Site-Cast Concrete Utilidor Lids

c. Manholes to include Sumps

d. Utilidor Construction

e. Alarm Lights and posts

f. Catwalks

g. Manhole expansion and reconstruction

h. Steel pipe support, seismic bracing, and anchorage system

1.4.2 Fabrication and Erection Drawings At least 30 days prior to casting any units, the Contractor shall submit complete fabrication and erection drawings and placement diagrams, and shall submit such other descriptive data as the Contracting Officer may require to demonstrate compliance with the contract requirements. The submittal shall also include the Contractor's proposed methods of curing and storing the units in the casting yard and complete details of its

33 60 02 - 5 25 January 2008


method of casting, handling, transporting, and erecting the units, including type and location of lifting devices. Fabrication and erection drawings shall contain plans showing the size and location of every blockout required for any opening in each unit. Openings include those necessary for mechanical or electrical work, or any other major physical interference. Fabrication and erection drawings shall include drawings showing placement of pipe supports, seismic bracing, alignment guides and anchors for manholes and utilidor sections. Fabrication and erection drawings and placement diagrams for all units shall be submitted at one time. No casting operations shall commence at a permanent or temporary on- or off-site fabrication plant until fabrication and erection drawings and placement diagrams have been received by the Contracting Officer.

1.4.3 Schedules of Work and Tests Required for Installation 1.4.4 Manufacturer's Catalog Data Catalog cuts, brochures, and product data verifying compliance with the contract for the following:

a. Insulation adhesive.

b. Insulation material.

c. Sealants

1.4.5 Materials Representative samples in the following quantities:

a. Urethane Membrane: 1 gallon

b. Construction Fabric: 1 square yard

1.4.6 Waterproofing Material Manufacturer's installation instructions and certificate of compliance shall be submitted before delivery of materials to the site. For bitumen, instructions shall specify acceptable range of bitumen application temperatures and the maximum temperature for holding bitumen in a heated condition.

1.5 CONCRETE WORK 1.5.1 Concrete Concrete shall be as specified in SECTION 03 30 04, CONCRETE FOR MINOR STRUCTURES.

1.6 PIPE INSERTS, ANCHORS AND SUPPORTS Pipe inserts, anchors and supports for all systems shall be as specified in SECTION 33 17 11 WATER DISTRIBUTION SYSTEMS IN UTILIDORS except that those for the steam system are specified in SECTION 33 57 12 HEAT DISTRIBUTION SYSTEMS IN UTILIDORS AND MANHOLES. The steel strut support system for the piping shown in the plans is generic only.

33 60 02 - 6 25 January 2008


1.6.1 Steel Strut Pipe Support System Design Calculations The Contractor shall submit design calculations and shop drawings for the steel strut system and seismic bracing system. Calculations shall be stamped and signed by an engineer registered in the State of Alaska.

1.6.2 Pipe Seismic Bracing The Contractor shall design the pipe seismic bracing in accordance with TI 809-04. Resistance to lateral forces induced by earthquakes shall be accomplished without consideration of friction resulting from gravity loads. See SECTION 13 48 00 SEISMIC PROTECTION FOR MISCELLANEOUS EQUIPMENT. Bracing for the following equipment shall be developed by the Contractor: All of the utilidor piping and appurtenance and, the steel strut pipe support system.

PART 2 PRODUCTS 2.1 COATINGS AND SEALANTS 2.1.1 Coal Tar Coating The coal tar coating shall be a self-priming, heavy duty, cold-applied, water resistant coating made from pitch derived from suitable tars, selected solvents, mineral fillers and special additives. The material shall be able to protect against the deteriorating effects of raw and industrial waste materials and hydrogen sulfide gas, and be suitable for application to all metal, concrete and board insulation surfaces which will be buried, immersed, or exposed. The coating shall be applied in accordance with the manufacturer's recommendations to include, but not limited to, priming and top coats. The coal tar coating shall be Bitumastic Super Service Black as manufactured by Carboline Company, or equal.

2.1.2 Asphalt Varnish Asphalt varnish shall conform to Federal Specification CID A-A-1632.

2.1.3 Utilidor Lid Seal Surfaces of joints to be in contact with mastic shall be dry and free of oil, grease, dirt, loose concrete particles, or other foreign substances. Trowel on a generous layer of "Fibered Roof Coating", ACE Hardware product #11975 or approved equal. Lay two runs of "Oakum" type filler material on top of wall, into the mastic as shown on the drawings. All lifting loops, hooks, or eyes shall be nondeformed, ASTM A 36/A 36M galvanized steel unless a stronger steel or superior finish is shown on the drawings

2.1.4 Sealant Sealant for pipe sleeves shall conform to Federal Specification FS TT-S-001543. Sealant for utilidor shall conform to ASTM C 920, Type II, Class A. The compound shall be supplied in pre-measured kit form for on-the-job mixing.

2.1.4.1 Primer Primer for sealant shall be as recommended by the sealant manufacturer.

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Primer shall have been tested for durability with the sealant to be used and on samples of the surfaces to be sealed.

2.1.4.2 Backstop Material Backstop materials shall be resilient urethane or polyvinyl chloride foam, closed-cell polyethylene foam, closed-cell sponge of vinyl or rubber, polychloroprene tubes or beads, polyisobutylene extrusions, oilless dry jute, or rope yarn. Backstop material shall be nonabsorbent, nonstaining, and compatible with the sealant used. Tube or rod stock shall be rolled into the joint cavity.

2.1.5 Zinc Oxide Primer Zinc oxide primer shall conform to SSPC Paint 25.

2.1.6 Galvanized Coating Repair shall conform to ASTM A 780 for damaged and uncoated areas of hot-dip galvanized coating.

2.2 INSULATION 2.2.1 Extruded Polystyrene Extruded polystyrene shall conform to ASTM C 578, Type IV.

2.3 WATERPROOFING 2.3.1 Asphalt ASTM D 449, Type II.

2.3.2 Coal-Tar ASTM D 450, Type II.

2.3.3 Primer ASTM D 41 for asphalt and ASTM D 43 for coal-tar pitch.

2.3.4 Insulation Board ASTM C 208, construction grade, 1/2-inch thick, asphalt saturated or coated; ASTM C 726, 7/16-inch thick; or prefabricated membrane board 1/8- or 1/4-inch thick, consisting of asphalt-saturated felt laminated under pressure to both sides or with felt laminated on the bottom and a fiberglass mat laminated on top with a mineral-filled asphalt core.

2.3.5 Urethane Industrial Membrane Urethane industrial membrane shall have the following properties:

PROPERTY DATA TEST METHOD Tensile strength, psi., min. 400 ASTM D 412 Extension to break, 96 min. 350 ASTM D 412, 100 mil sheet Tear Strength, min. 90 ASTM D 624, Die "C"

33 60 02 - 8 25 January 2008


PROPERTY DATA TEST METHOD Softening Point, Ring & Ball, degrees F min. 143 ASTM D 36-95 Brittleness Temp, degrees F min. 46 ASTM D 648 Hardness, Shore A, min. 50 ASTM D 2240 @ 77 degrees F Permeability to Water Vapor, 0.06 ASTM E 96-Method E (100 Perms) mil sheet, 100 degrees F) Abrasion Resistance - Wt. Loss, mg., max. 1.5 Taber Abraser, CS-17 Wheel, 1000 gr/1000 rev, ASTM C 501 2.4 CONSTRUCTION FABRIC Construction fabric shall meet the following requirements:

PROPERTY DATA TEST METHOD Thickness, mils, min. 100 ASTM D 1777 Mullen Burst Strength, psi, min. 400 ASTM D 751 Diaphragm Method Trapezoidal Tear Strength, lbs., min. 90 ASTM D 751 Puncture Resistance, lbs., min. 120 ASTM D 751 Elongation at 250 lb. Load, percent, max. 150 ASTM D 5034 2.5 STEEL AND MISCELLANEOUS METAL Steel and miscellaneous metal not otherwise specified shall conform to SECTION 05 50 00, METALS: MISCELLANEOUS AND FABRICATIONS.

2.6 SUPPORT RACK AND INSERT SYSTEM Steel strut system supports shall be manufactured from ASTM A 570, Grade 33, 12 gauge hot dipped galvanized steel in accordance with ASTM A 123/A 123M. System shall be rated for a minimum 1500 lb point loading. To inhibit concrete seepage in concrete inserts system shall include closure and end caps or foam filler. Strut system shall be coordinated with and accommodate pipe rollers as specified.

2.6.1 Pipe Rollers Pipe rollers shall conform to MSS SP-58 and MSS SP-69 type 41, 44 or 46. Pipe rollers shall be one-piece cast iron type rollers. Split two-piece and aluminum rollers shall not be allowed. Teflon slide plate type supports shall not be allowed.

2.7 SUMP PUMPS

Sump pumps shall be rated 20 gpm at a total dynamic head of 20 ft plus or minus 10 percent. They shall have permanently lubricated bearings. Sump

33 60 02 - 9 25 January 2008


pumps shall be of the submersible type capable of operating while completely submerged and shall be electronically driven. The pump and motor shall be capable of pumping liquids at a temperature of 200 degree F. The pump shaft shall be stainless steel, with bronze or cast iron impeller and screened inlet, and with a housing of close-grained cast iron or bronze. The unit shall be capable of passing a 3 inch solid (sphere). The motor shall have sufficient power for the service required, and shall be furnished complete with overload protection in separate ungrounded conductor. The pump shall be automatically controlled by a submersible switch assembly. Wiring from switch to pump shall be waterproof type cord suitable for submersion in 200 degrees F liquids. Unit shall be provided complete, single, point electrical connection, with all required control equipment. Motor shall be 120 volt, single phase, Gould model 3886 or approved equal.

PART 3 EXECUTION 3.1 MANHOLES AND ACCESSORIES 3.1.1 General New manholes shall be field constructed, reinforced concrete type. Existing manholes shall be modified as shown on the drawings. Where connections to existing utilidors or manholes are required, the Contractor shall break open the utilidor or manhole to the minimum extent necessary for adequate tying of the new construction to the old. All steel bars shall be thoroughly cleaned before placing any concrete. Before any new concrete is placed against the old concrete, the surface of the latter shall be cleaned of all debris and loose material and a coating of neat cement grout applied just prior to placing the new concrete. No structures and/or appurtenances shall be supported from manhole tops other than the access ladder, electrical hardware, and any structure specifically shown on the drawings as being supported from the manhole tops.

3.1.2 Manhole Construction and Accessories The manholes shall be constructed of reinforced concrete. Manhole side walls shall be constructed by one monolithic pour.

3.1.2.1 Dimensions Manhole dimensions shall be as indicated and in all cases shall provide sufficient room for maintenance. Manhole sumps shall be 2 feet deep by 2 feet in diameter unless shown otherwise. At the Contractor's option, the sump may be a 2 feet deep by 2 feet square. At the Contractor's option, the sump may be a Schedule 40 steel pipe, 26 inches in diameter. The pipe shall be closed at the bottom by either a 0.5 inch steel plate or a 4 inch thick, reinforced concrete base. The pipe shall be locked into manhole floor and PCC base. The finished depth of the sump shall be 2 feet. The pipe sump shall be coated with a coal tar coating.

3.1.2.2 Manhole Ladders Manholes shall be provided with straight-type steel ladder(s) not less than 16 inches in width with 7/8-inch diameter rungs spaced 12 inches apart. Bar side rails shall be 2 inch x 1/2 inch steel. The ladder shall be adequately anchored to the wall by means of steel inserts spaced not more than 6 feet apart vertically, or as shown on the drawings, and shall be so installed as to provide at least 6-1/2 inches

33 60 02 - 10 25 January 2008


of toe space between the wall and the inside of the rungs. When the inside of the manhole is insulated, the 6-1/2 inch spacing shall be between the insulation and the inside of the rungs. The wall along the line of the ladder shall be vertical its entire height. Ladders anchored to manhole bottoms shall have the bottom 12 inches covered with coal tar coating.

3.1.2.3 Fire Hydrant Manhole Frames and Covers Frames and covers shall be of the solid lid type and conform to the applicable portions of Federal Specification FS A-A-60005. Frames and covers shall:

a. Have a minimum masonry contact of 3 inches overlap.

b. Be constructed of ductile iron or gray iron.

c. Have a clear access of 24 inches or as indicated on the drawings.

d. Have hatches covered with one round lid.

e. Have external (non-recessed) butt-type hinges securely attached to the

frame that shall not work loose under repeated opening and closing of the lids.

f. Have fixed protruding handle with a minimum clear hand opening of 5

inches by 2 1/2 inches. Frames and covers shall be proof-load tested in accordance with Federal Specification FS A-A-60005. Loading shall be for 1,000 pounds. Frames and covers shall be R-6320 Series as manufactured by Neenah Foundry Company of Neenah, as modified above, or equal.

3.1.2.4 Manhole Doors Door Lids with frames shall be Aluminum "Bilco Type J-AL or JD-AL" vault doors or approved equal, dimensioned as shown on drawings. The vault access shall be single leaf, pre-assembled from the manufacturer. Doors shall fit into the existing access hatch and shall be fastened with 3/8 inch expansion anchors drilled and fastened into existing frame and concrete.

a. Lifting mechanisms: Doors shall have the required number and size of

compression spring operators enclosed in telescopic tubes to provide, smooth, easy and controlled cover operation though the entire arc of opening and to act as a check in retarding downward motion of the cover when closing. The upper tube shall be the outer tube to prevent accumulation of moisture, grit, and debris inside the lower tube assembly.

b. A removable exterior turn/lift handle with a spring loaded ball detent

shall be provided to open the cover and the latch release protected by a flush, gasketed, removable screw plug.

c. Cover shall be equipped with a steel hold open arm which automatically

locks the cover in the open position. d. Compression spring tubes shall be an anti-corrosive composite material,

hinges and steel snap lock shall be Type 316 stainless steel.

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3.1.2.5 Sump Pumps Manholes so indicated on the drawings shall a sump and sump pump. The motor shall have sufficient power for the service required, and shall be furnished complete with overload protection in separated ungrounded conductor. They shall have permanently lubricated bearings. Sump pumps shall be of the submersible type capable of operating while completely submerged and shall be electrically driven. The pump and motor shall be capable of pumping liquids at a temperature of 200 degrees F. The pump shaft shall be stainless steel, with bronze or cast iron impeller and screened inlet, and with a housing of close-grained cast iron or of bronze. The unit shall be capable of passing a 3/8 inch solid (sphere). The motor shall have sufficient power for the service required, and shall be furnished complete with overload protection in separate ungrounded conductor. The pump shall be automatically controlled by a submersible switch assembly. Wiring from switch to pump shall be waterproof type cord suitable for submersion in 200 degrees F liquids. Unit shall be provided complete, single point electrical connection, with all required control equipment. Provide a third float level to be visible from the road. Provide a third float level to indicate emergency high level to be connected to an emergency warning light mounted on the manhole. The warning light shall be mounted to be visible from the road. The light shall be mounted on a 4 inch diameter pipe securely attached to the manhole top. The pipe shall be a minimum of 12 inches long and a maximum of 10 feet long. It shall be capped at the top and have drain holes at the bottom. It shall be primed and painted safety yellow. The on-off levels shall be set according to the manufacturer's recommendations. The alarm level shall be set 26 inches above the sump bottom. Manufacturer shall verify and provide written certification of all special requirements noted herein.

3.2 CONCRETE UTILIDOR SYSTEM 3.2.1 General A concrete utilidor system shall be provided and installed with removable lids as shown in detail on the drawings. Lids for utilidors in general shall be precast. The walls and floor slabs shall be either monolithic construction, placed with construction joints between bottom and sides or placed with construction joints between sides and a starter wall cast into the bottom. No structures and/or appurtenances shall be supported from the utilidor lids.

3.2.2 Concrete Utilidor Lids Concrete utilidor lids shall be flat and true at all locations where contact on utilidor wall is to be made. Concrete utilidor lids with defects which affect the strength of the cover unit, or which are warped, honeycombed, contain visible air pockets, exposed aggregate or other surface defects such as spalled, chipped or broken edges shall not be installed. Handling and conveying before curing shall be reduced to a minimum by use of methods designed to prevent bending or shock likely to produce incipient cracks or other deformities. All lifting loops or eyes shall be nondeformed, ASTM A 36/A 36M galvanized steel unless a stronger steel or superior finish is shown on the drawings.

The joint where the sides of the utilidor top meets the utilidor lid shall be thoroughly cleaned, dry, free of oil, grease, dirt, loose concrete particles, or other foreign substances. Trowel on a generous (approximately 3/4" high by 4" wide) layer of "fibered Roof Coating", ACE

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Hardware product #11975, or equal. Lay two runs of "Oakum" type filler material on top of wall, into the mastic.

3.2.3 Concrete Utilidor Construction The concrete utilidor system shall be of various sizes to accommodate the different piping arrangements as indicated. The concrete utilidor wall top dimensions are critical to provide a tight fitting system. Contractor shall use extreme caution when forming and placing inside edge and top of walls to provide smooth even surfaces to accommodate utilidor lids.

3.2.4 Final Elevations The concrete utilidor floor shall slope continuously and drain toward manholes. The Contractor shall set the concrete utilidor at the elevation shown on the drawings and shall grade the adjacent areas. Any cut or fill areas adjacent to the concrete utilidor shall be graded back to the existing grade as indicated. There shall be no surface depressions which might prevent free surface drainage away from the utilidor. Final elevations shall be approved by the Contracting Officer. Once the final elevation is set, the concrete utilidor floor and piping must maintain constant slope to drain toward a manhole.

3.2.5 Coordination With Existing Utilities Before beginning work in a given area, the Contractor shall become familiar with all known utility locations shown and expose those existing underground utilities to verify existing conditions to determine any conflicts with the work, and to plan his work accordingly. The actual concrete utilidor routing may be offset or changed if approved by the Contracting Officer in order to reduce conflicts, interruptions, expedite the work, or for any other reason to the mutual benefit of the Contractor and the Government.

3.2.6 Utilidor Cut-Off Wall The utilidor shall be completely blocked off (flush with the interior surface of the Mechanical Room) where the utilidor enters a building. The wall shall be constructed of concrete block or poured-in-place concrete. Pipes shall pass through cut-off walls with pipe sleeves. No weep holes or open spaces shall pass through the cut-off wall.

3.3 PIPE SLEEVE REQUIREMENTS Pipes and conduits passing through concrete walls, floors, or tops shall be provided with pipe sleeves fitted into place at the time of construction. The space between the pipe and sleeve shall be filled with back-up material and sealed flush with both inside and outside surfaces with a 3/8-inchdeep bead of sealant. Sleeves shall not be installed in structural members, except where indicated or approved. Each sleeve shall extend through its respective wall, floor or top, and shall be cut flush with each surface, except for special circumstances. Unless otherwise indicated, sleeves shall be of size to provide a minimum of 1/4-inch clearance all-around between bare pipe and inside of sleeve or between jacket over insulation and sleeves. Sleeves shall be steel pipe, cast-iron pipe, or ductile iron pipe.

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3.4 PIPE SUPPORT RACK Pipe racks in utilidors shall be 1-5/8 inch wide continuous slotted channels (Unistrut, or equal), metal framing systems, using nut and bolt connections of fittings and hardware to the slotted channels. As an alternative, the pipe support system may be an engineered system stamped and signed by a registered professional engineer. In new concrete construction, the wall supports shall be embedded in concrete. The Contractor shall provide pipe rack configurations as necessary throughout the project, and shall include, in his shop drawing submittal, drawings with dimensions showing clearances from support members to piping systems, pipe rack dimensions, maintenance access aisle, components and fittings proposed for use. Bottom of supports shall not rest in drainage trench in utilidor bottom.

3.5 WATERPROOFING The below ground exterior of all concrete manhole and utilidor side and lids shall be waterproofed in accordance with this paragraph. Waterproofing shall extend a minimum of 2 feet beyond construction joints with existing utilidor and manholes. Waterproof all existing below ground manhole exposed in the course of constructing new access shafts, ceilings, and expanding existing manhole chambers. The utilidor walls exposed in the course of removing lids to access utilidor piping shall not be waterproofed as described in this paragraph.

3.5.1 Delivery and Storage Materials shall be delivered to the job site in their original unopened packages, clearly marked with the manufacturer's name, brand name, and description of contents. Materials shall be stored in clean, dry areas, away from excessive heat, sparks, and open flame. Storage area shall be ventilated to prevent build-up of flammable gases. Materials shall be maintained at not less than 50 degrees F for at least 24 hours before use.

3.5.2 Preparation Preparation of surfaces to be waterproofed shall be as specified in SECTION 03 30 04, CONCRETE FOR MINOR STRUCTURES. Items that penetrate the membrane shall be installed before waterproofing is applied. Surfaces shall be smooth and swept thoroughly to remove foreign materials immediately before waterproofing is applied.

3.5.3 Waterproofing Waterproofing shall consist of the appropriate number of coatings of either bitumen or urethane membrane as specified herein.

3.5.3.1 Bituminous Waterproofing a. Application: Waterproofing shall not be applied if frothing or

bubbling occurs when hot bitumen is applied to the surface. The hot bitumen must stick tightly to the surface. When waterproofing in an enclosed space, adequate ventilation shall be provided. Waterproofing shall be one layer of primer and one layer of asphalt or coal-tar, applied in solid moppings. Waterproofing shall be applied when the ambient temperature is 40 degrees F or above. Asphalt shall not be heated above 450 degrees F nor coal tar above 375 degrees F. Heating kettles and tanks shall be provided with automatic thermostatic control

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capable of maintaining bitumen temperature. Temperature of bitumen at time of application shall be in accordance with the bitumen manufacturer's recommendation. Temperature shall be measured with portable thermometer at the point of application immediately before its use. Bitumen with a temperature not conforming to the manufacturer's recommendations shall be returned to the kettle. Bitumen overheated by more than 50 degrees F for more than 1 hour shall be removed from the site.

b. Priming: Surfaces shall be coated uniformly with primer at the rate

recommended by the manufacturer. c. Projections and Flashing: All pipes, pipe sleeves, and other similar

projections through the membrane shall be made watertight, and all flashings and similar construction shall be mopped thoroughly in place.

d. Coating: Coating shall be applied uniformly at the rate of not less

than 60 pounds of asphalt or 70 pounds of coal-tar per square. Brooms shall have soft bristles and shall be discarded when bitumen buildup on the fibers prevents application of equal pressure across the broom width.

e. Protection: Waterproofing against which backfill is to be placed shall

be protected by a single thickness of insulation board, unless insulated with polystyrene or cellular glass in accordance with other sections of this specification. The insulation board shall be pressed into the final mopping while the bitumen is still hot, with edges of boards brought into moderate contact and joints staggered. Where surfaced insulation board is used, the surfaced side shall face outward. Boards shall be carefully and neatly fitted around projections and shall cover the entire surface of the waterproofing. Waterproofing not covered with insulation fiberboards shall be protected as necessary to prevent damage from subsequent building operations.

3.5.3.2 Urethane Industrial Membrane System Installation shall comply with the manufacturer's instructions, except as otherwise specified. The membrane shall bond to concrete. Application shall be in two coats minimum with successive coats applied at right angles to the preceeding coat. Finished thickness of the membrane shall be 40 mils, minimum.

a. Projections and Flashings: All pipes, pipe sleeves, and other similar

projections through the membrane shall be made watertight, and all flashings and similar construction shall be secured thoroughly in place.

b. Protection: Waterproofing against which backfill is to be placed shall

be protected by a single layer of construction fabric. Construction fabric shall be carefully and neatly fitted around projections and shall cover the entire surface of the waterproofing.

3.5.3 Equipment Calibration (For Two-Component Systems Only) Spray equipment for two-component systems shall be calibrated each day at start of operations, after each restart if spraying operations have been terminated for more than 1 hour, wherever there is a change in fan pattern

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or pressure, whenever slow curing areas are noticed, whenever a change is made in hose length or working height and after changeover between materials. Calibration shall consist of demonstrating that the equipment is adjusted to deliver components in the proper proportions. Calibration tests shall be done on the utilidor section adjacent to the area to be sprayed.

3.6 PAINTING AND FINISHING 3.6.1 Ferrous Metal Surfaces Inside Utilidors and Manholes All ferrous metal surfaces in utilidors and manholes, excluding piping, but including racks, supports, hangers, and covers, shall be treated by the following method unless specifically directed otherwise in the project specifications:

Items shall be galvanized coated with ASTM B 633, Type I, Class Fe/Zn 25; or ASTM A 153/A 153M, Class A.

Racks, hangers, and support system shall be galvanized by the following method.

All pipe hangers and supports shall be hot-dip galvanized after fabrication to provide a Coating Grade of 65 (average zinc coating of 1.5 ounces/square foot) in accordance with ASTM A 123/A 123M.

Ladders shall be galvanized.

If surfaces have been shop-coated, the shop coat shall be thoroughly cleaned and touched-up at corroded, scarred, abraded surfaces, cut edges, exposed threads, or welded areas as follows: areas shall be given two coats (minimum) of cold galvanizing compound in accordance with manufacturer's recommendations.

3.6.2 Ferrous Metal Surfaces Outside Manholes All ferrous metal surfaces outside manholes shall be painted in accordance with the PAINTING, GENERAL section.

3.7 INSULATION The utilidors and manholes shall be insulated as shown and as hereinafter specified. Insulation shall be kept dry at all times and protected from weather and moisture before and after installation. Polystyrene insulation shall not be left exposed to direct sunlight for a combined period greater than 24 hours.

3.7.1 Requirements The surfaces to be insulated shall be covered with extruded polystyrene. Exterior insulation for utilidors with traffic lids shall have the added requirement of 60 psi minimum compressive strength.

3.7.2 Installation of Insulation 3.7.2.1 Exterior Surfaces Insulation shall be attached to exterior surfaces with an adhesive as recommended by the insulation manufacturer. If bituminous waterproofing is

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used, it shall be still hot during insulation installation. a. Finish: Joints between blocks shall be buttered with insulation

manufacturer's recommended mastic compatible with the waterproofing material, and blocks shall be butted snugly together. The insulation shall be protected during backfill operations to prevent any damage. Damaged insulation shall be replaced at no cost to the Government.

b. Openings: Openings in insulation around lifting loops, vents, and

other protrusions shall be filled and cemented flush with the face of the insulation, with mastic as specified above.

3.7.2.2 Interior Surfaces Insulation shall be attached to interior surfaces, where indicated on the drawings, with an adhesive as recommended by the insulation manufacturer. Insulation shall also be attached with mechanical fasteners as recommended by the insulation manufacturer. Mechanical fasteners shall include a washer with a minimum surface area of 5 square inches. Mechanical fasteners shall be placed one per every 6 square feet of insulation (minimum).

3.8 QUALITY PROVISIONS 3.8.1 General Tests shall be conducted before, during and after the installation of the system. All instruments, equipment, facilities, and labor required to properly conduct the tests shall be provided by the Contractor.

3.8.2 Field Tests The following field test shall be conducted when applicable to the system involved. If any failures occur, the Contractor shall make adjustments or replacements as the Contracting Officer may direct, and the tests shall be repeated until satisfactory installation and operation are achieved.

3.8.2.1 Equipment All pumps, alarms, controls, and any other operable items of equipment shall be operated to verify proper operation and compliance with the specifications.

3.8.3 Heating and Temperature Monitoring Plan The Contractor shall submit his plan for heating and temperature monitoring for the utilidor system. This plan shall include, but not be limited to: heater types and locations, monitor types and locations, inspection schedule, and contingency plan.

3.9 CLEANING OF UTILIDOR SYSTEM After tests are completed, and before utilidor covers are placed, the utilidors, sumps, and manholes shall be broom-cleaned of dirt and debris to the satisfaction of the Contracting Officer. Utilidor lids shall be placed and sealed immediately after approval by the Contracting Officer.


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