Township of Allamuchy, NJ Specifications for Water Main Construction

All ductile iron pipe shall be centrifugally cast pipe conforming to the American National Standard for Ductile Iron Pipe, Centrifugally Cast in Metal Molds or Sand-Lined Molds for Water or Other Liquids, ANSI/AWWA Designation A21.51/C-151, latest revision. Pipe sizes shall be as shown on the contract drawings with a thickness class of 52, unless otherwise indicated on the plans. All pipe fittings shall have joints with body thickness and radii of curvature conforming to ANSI/AWWA Designation A21.10/C-110, latest edition.

Joints shall employ a single, elongated gasket of such size and shape as to provide an adequate compressive force against the spigot and socket after assembly to effect a positive seal under all combinations of joint and gasket tolerances. Joints shall be U.S. Pipe and Foundry Company's "Tyton" joint, Griffin Pipe Products Company's "Super Bell-Tite" joint, or approved equal conforming to American National Standard for Rubber Gasket Joints for Cast Iron and Ductile Iron Pressure Pipe and Fittings, ANSI/AWWA Designation A21. 11/C.111, latest edition. Gaskets shall be vulcanized natural or vulcanized synthetic rubber, resistant to common ingredients of sewage, industrial wastes, including oils and groundwater. Gaskets shall be free of porous areas, foreign material, and visible defects. Joint lubricants shall be suitable for lubricating the joint assembly. Parts shall be nontoxic, shall not support the growth of bacteria and shall have no deteriorating effects on the gasket material.

All ductile iron pipe shall be externally coated with a uniform thickness (approximately one millimeter thick) of hot-applied coal tar coating. The finished coating shall be neither brittle when cold, nor sticky when exposed to the sun, and shall be strongly adherent to the pipe. The pipe interior shall have cement mortar lining and bituminous sealed coating in accordance with the latest ANSI/AWWA Designation A21.4/C-104 for Cement-Mortar Lining for Cast Iron and Ductile Iron Pipe and Fittings for Water.

In areas where the contract drawings call for restrained joints, joints shall be ductile iron mechanical joints utilizing MegaLug retainer glands, as manufactured by EBAA Iron. Field lok gaskets, as manufactured by U.S. Pipe, or approved equal, may be utilized to restrain joints on mechanical joint piping runs where approved by the Engineer. All gate valves and fittings shall be restrained utilizing MegaLug retainer glands. The assembly of all piping and fittings shall be inspected prior to backfill.

In areas where the mechanical joint set screw retainer glands are required, joints shall be ductile iron mechanical joints utilizing MegaLug retainer glands. Mechanical joint restraint shall be incorporated into the design of the follower gland. The restraining mechanism shall consist of individually actuated wedges that increase their resistance to pull-out as pressure or external forces increase. The device shall be capable of full mechanical joint deflection during assembly and the flexibility of the joint shall be maintained after burial. The joint restraint ring and its wedging components shall be made of grade 60-42-10 ductile iron conforming to ASTM A536-84. The wedges shall be ductile iron heat treated to a minimum hardness of 370 BHN. Dimensions of the gland shall be such that it can be used with the standardized mechanical joint bell conforming to ANSI/AWWA C111/A21.11 and ANSI/AWWA C153/A21.53 of the latest revision.

Torque limiting twist-off nuts shall be used to insure proper actuation of the restraining wedges. They shall have rated working pressures of 350 psi in sizes sixteen-inch and smaller and 250 psi in sizes eighteen-inch through forty-eight-inch. The devices shall be listed by Underwriters Laboratories up through the twenty-four-inch size and approved by Factory Mutual up through the twelve-inch size. The restraint shall be the Series 1100 MEGALUG® restraint as produced by EBBAA Iron, Inc. or approved equal.

Additional restraint will be provided if thrust conditions are created due to horizontal and/or vertical adjustment to the pipeline due to field conditions. The length of restraint stall be determined by the Engineer and is dependent upon the depth, test pressure, and type of fitting. A minimum of three full lengths of pipe stall be restrained before and after every fitting. Mechanical joints shall conform with AWWA C111, latest revision thereof.

(8)

The use of field lok gaskets, as manufactured by US-Pipe, may be used in straight runs of push-on joint pipe where restraint is required. The use of field lok gaskets shall be approved by the Engineer prior to installation. Field lok gaskets must be visually inspected by the Township prior to the pipes being put together

Compression - sleeve coupling.

Couplings shall be designed to couple plain end piping by compression of a ring gasket at each end of the adjoining pipe sections. The coupling shall consist of one middle ring flared or beveled at each end to provide a gasket seat; two follower rings; two resilient tapered rubber gaskets; and bolts and nuts to draw the follower rings toward each other to compress the gaskets. The middle and the follower rings shall be true circular sections free from irregularities, flat spots, and surface defects, and the design shall be such as to provide for confinement and compression of the gaskets. For cast gray and ductile iron piping the middle ring shall be of cast iron or steel and the follower rings shall be of malleable iron.

Cast iron shall conform to ASTM A48 and shall be not less than Class 25. Malleable iron shall conform to ASTM A47. Gaskets shall be designed for long life and resistance to set after installation and shall meet the applicable requirements specified for gaskets for mechanical joint in ANSI A21.11 (AWWA C111). Bolts shall be track-head type; bolts and nuts shall conform to the tensile requirements of ASTM A307, Grade A; or bolts shall be round head square neck type conforming to ANSI B18.5 with hex nuts conforming to ANSI/B18.2.2. Bolts shall be 5/8 inch in diameter; minimum number of bolts for each coupling shall be as recommended by the manufacturer.

Bolt holes in follower rings shall be of a shape to hold fast the necks of the bolts used. Sleeve type mechanical coupling shall not be used as an optional method of joining except where pipeline is adequately anchored to resist tension pull across the joint.

Cast/ductile iron fittings.

Ductile iron fittings shall be cement lined, mechanical joint, meeting the American National Standard for Ductile Iron Compact Fittings for Water Service, ANSI/AWWA C153 latest revision. Mechanical joints shall conform with latest revision for ANSI/AWWA C111/A21.11 Rubber Gasket Joints for Ductile Iron and Gray Iron Pressure Pipe and Fittings. Hydrant tees shall be mechanical joint tees. Cement lining shall conform to ANSI/AWWA C104, latest revision Cement Mortar Lining for Ductile Iron Pipe and Fittings for Water and shall include a bituminous seal coat. The exterior surface of fittings shall receive a standard foundry coal tar dip coating, product to meet with EPA approval. Fittings up to and including twenty-four-inch size shall be 350 psi pressure rating and fittings over twenty-four-inch shall be ductile iron with a pressure rating class of 250 psi. All mechanical joint fittings shall be supplied with ductile MegaLug retainer glands conforming with the applicable requirements in § 296-39A, including pipe restraint.

Solid sleeve mechanical joint couplings shall be used where joining pipes of the same outside diameter and material. Pipe couplings shall be Tyler/Union Ductile Iron C-110 Full Body Mechanical Joint fitting or C-152 Compact Ductile Iron fitting or approved equal and shall be utilized where joining pipes of different outside diameters. Pipe couplings shall consist of steel middle ring, two steel follower rings, resilient gaskets and bolts. Single panel repair clamps are not suitable alternates.

Standard body fittings conforming to the latest revision of ANSI/AWWA C110, Ductile Iron and Gray Iron Fittings, three-inch through forty-eight-inch for water and other liquids may be used where approved by the Engineer.

All fittings shall be U.S. made. Substitutions will be reviewed for conformance with all pertinent specifications at the contractor's expense.

Gate valves.

Gate valves shall be iron body, inside screw, fully bronze-mounted, conforming with the applicable requirements of AWWA Standard for Resilient Seated Gate Valves, for Water Service of the American Water Works Association (AWWA C509, latest revision). Valve interior and exterior shall be coated with a 10 mil thickness epoxy coating which meets or exceeds all applicable requirements of AWWA C550 and is certified to ANSI/NSF 61. Disc shall be symmetrical iron wedge, fully encapsulated with molded rubber, no exposed iron.

Valves in sizes three-inch to twelve-inch shall be suitable for water working pressures to 250 psi and test pressures to 500 psi.

The operating nut shall be square, measuring 1 - 15/16 inch at the top, two-inch at the base and shall be 1 3/4-inch high. An arrow showing the direction of opening and the word "OPEN" shall be cast on the flange of the operating nut. Valves shall open counter-clockwise.

Valves in sizes three-inch to twelve-inch shall be vertical and shall be provided with mechanical joint ends and MegaLug retainer glands.

MegaLug retainer glands shall be ductile iron, Underwriters Laboratory approved and conform with the applicable requirements in § 296-39A, as manufactured by EBAA Iron, Inc., or approved equal.

Lubrication instructions and parts lists shall be furnished in triplicate for each type and manufacture.

Valves shall be Resilient Wedge Gate Valves Model A-2360 as manufactured by the Mueller Company.

(8)

Each buried valve shall be provided with a Tyler/Union Series 6855 Part # 564-A cast iron, two piece, slide type valve box. Valve boxes shall be 5-1/4-inch shaft with a round base and shall be provided with extra deep cast iron covers with the word "WATER" cast on.

(9)

Length of valve boxes and size of base shall be to suit each particular installation and shall have about eight inches of adjustment up and down available after setting to grade.

(10)

Valve boxes shall be as manufactured by Tyler/Union or approved equal.

(11)

All valves and valve boxes shall be U.S.A. made. Substitutions will be reviewed for conformance with all pertinent specifications at the contractor's expense.

Fire hydrants.

Hydrants shall be of 5 1/4-inch size, conforming to the standards of the American Water Works Association, AWWA Standard for Dry-Barrel Fire Hydrants for Ordinary Water Works Service, AWWA C502, latest revision, relating to fire hydrants.

Hydrants shall be of a two-piece design with a breakaway flange located at the ground line. Hydrants shall be provided with a six-inch diameter mechanical joint connection with MegaLug restraint and shall be set with the breakaway flange as shown on the contract drawings. Extensions, as required, shall be furnished and installed by the contractor.

Hydrants shall be of the safety flange type with six-inch mechanical joint connection, 5 1/4-inch main valve opening, 2 1/2-inch hose connections with National Standard threads and one 4 1/2-inch steamer nozzle to fit the owner's standard dye. Hydrants shall have O-ring seals and the main valve shall close clockwise. All hydrants shall be painted with two coats of red paint.

All parts of hydrants shall be interchangeable with similar parts of hydrants of the same size and type. All bolt holes shall be accurately drilled from templates. All joints shall be faced smooth, so as to make a perfectly watertight joint.

Hydrants shall be provided with O-ring seals. Each hydrant shall be shop tested under 300 psi applied above and below the compression valve. Any hydrant showing sweating of metal or leaking or other defect shall be rejected. All tests shall be made at the expense of the supplier.

Hydrants shall be "Centurian Model A-423" as manufactured by the Mueller Company.

Tapping/inserting sleeves and valves.

Tapping/inserting sleeves shall be extra heavy pattern of the sizes suitable for use on the pipe on which the respective sleeve is to be installed and for use with the tapping/inserting valves. They shall be designed for a working pressure of 250 psi and of the same manufacturer as the tapping/inserting valves. Cast iron sleeves shall be as manufactured by Mueller Company or an approved equal.

Tapping/inserting valves shall be of the same manufacturer as the tapping sleeves and meet all requirements for "gate valves" previously specified.

Plastic pipe encasement. Plastic pipe encasement for use with ductile iron pipe shall be polyethylene eight mil. thick either in tube or sheet form with two-inch wide polyethylene adhesive tape used to secure the film to the pipe.

Concrete pipe encasement.

Concrete encasement work shall include the construction of nonreinforced structures used for encasement or plugging purposes, as indicated on the construction plans, and as directed by the Engineer.

Concrete shall have a minimum twenty-eight-day compressive strength of 2,500 pounds per square inch. All materials shall conform to the applicable provisions of the latest edition of the American Concrete Institute Standards (ACI Standard 318, Building Code Requirements for Reinforced Concrete).

Concrete thrust blocks. Concrete for thrust blocks shall be Class "C" concrete conforming to the NJDOT's Standard Specifications for Road and Bridge Construction, as currently amended.

Broken stone. Unless otherwise approved by the Engineer, clean broken stone shall be installed as bedding for all valves and hydrants. Clean broken stone shall be nominal 3/4-inch size conforming to the requirements in the NJDOT's Specifications for Road and Bridge Construction.

Steel pipe (bridge crossing). All welded steel pipe shall conform to the requirements of AWWA Standard for Fabricated Electrically Welded pipe, C-201 latest edition. Fittings, flanges, and similar parts shall conform to the latest requirements of applicable AWWA Standards. Minimum pipe thickness shall be 3/8 of an inch. Field welding shall conform to the requirements of AWWA Standard for Field Welding of Steel Water Pipe Joints, C-206, latest edition.

Service connections.

The copper tubing shall be 3/4-inch or larger Type K and conform with ASTM Designation B-88, latest revision.

Curb valves and boxes shall be provided on all service connections at the right-of-way line. Curb valves shall be bronze body, stem and key with resilient O-rings. Curb valves shall be rated for a 250 psi working pressure and shall be Mueller No. B-25209 Ball Valves without drains. Valve boxes shall be cast iron extension type with one-inch inside diameter upper section, stationary rod extensions and arch pattern base for fitting over the curb valve. For service lines larger than one-inch the contractor shall install a Tyler/Union Series 6855 part # 564-A main line valve box. The top of the valve box shall be set flush with finish grade. Valve boxes shall not be installed in sidewalk or curb areas. Valve boxes shall be Model # H-10314 as manufactured by the Mueller Company, with Model 88033 stainless steel rod.

Corporations shall be bronze body, key and stem with resilient O-ring seals conforming with AWWA C800-84, latest revision Underground Service Line Valves and Fittings. Corporations shall have threaded inlets and compression fitting outlets suitable for use with Type K copper tubing. Corporations shall be Model B-25008 as manufactured by the Mueller Company or approved equal.

Sizes of corporation stops shall be as required to reconnect existing service connections from the existing water mains to the proposed mains.

Multiple taps at a single location shall be at least 18 inches apart and staggered as far as angle to the spring line on water main to avoid pipe damage (to prevent weakening pipe).

§ 296-40 Methods of construction.

Cutting and removing pavement.

The line between the trench and the existing pavement to remain shall be cut with a saw, pneumatically operated spade, or approved equal, so as to leave a smooth, straight, and vertical edge. The existing pavement may be bituminous, brick, block, nonreinforced concrete, reinforced concrete, etc. The excavated pavement shall be broken up and removed to a site approved by the Engineer.

Where excavations are to be made on concrete roads, the existing concrete shall first be saw cut and removed. All protruding reinforcing rods shall be cut off and removed. Any loose or broken longitudinal portions of adjacent existing lanes shall be removed and replaced as directed by the Engineer.

Underground utilities.

It is the responsibility of the contractor to verify the location of all existing utilities whether shown on the plans or not.

Whenever a utility line is crossed or in any way exposed during this construction, the contractor shall brace the utility line in accordance with the standard detail "support of utilities" or to the satisfaction of the owner of the utility. The utility line shall be supported as soon as the existing support is removed and until the trench is backfilled.

Excavation.

The trench shall be excavated along the lines designated by the Engineer and to a depth sufficient to provide a cover over the mains of not less than four feet except where greater or lesser depths of cover are shown on the detailed plans or are necessary due to the existence of utilities or to connect to existing lines. The trench shall be not less than one foot and not more than two feet wider at the bottom than the outside diameter of the pipe. The bottom of the trench under each joint shall be so hollowed out to allow the body of the pipe to have bearing along the entire length of trench if and where the trench is excavated at any place below the proper grade, excepting at joints, it shall be refilled to grade with sand or loam and thoroughly compacted.

The Engineer shall have the right to limit (to 100 feet maximum) the amount of trench which shall be opened in advance of the completed pipe laying work and to limit (to 200 feet maximum) the amount of trench left unfilled, backfilled and unpaved.

The material excavated shall be laid compactly on the side of the trench and kept trimmed up so that it will be of as little inconvenience as possible to the traveling public and to adjoining tenants. Where the streets are paved, the paving material shall be kept separate from the other materials excavated. All streets shall be kept open for travel unless otherwise approved by the Engineer.

All clean excavated material shall be deposited at locations approved by the Engineer.

All debris and unsuitable material shall be removed and deposited at a location provided by the contractor and approved by the Engineer. The Engineer alone shall determine if excess material is clean or not.

If, in the opinion of the Engineer, the material at or below the grade to which excavation would normally be carried is unsuitable for foundation, or if the material from any other part of the trench is unsuitable for backfill, it shall be replaced with suitable surplus material excavated from other parts of the project or select backfill imported to the site as specified below.

If suitable surplus material is not available from other parts of the project, then the contractor shall furnish suitable material if and where directed by the Engineer.

Sheeting. The contractor shall furnish, install in place and maintain such sheeting and bracing, etc., as may be required to support the sides of the excavation and to prevent any movement of earth which could in any way diminish the width of the excavation below that necessary for proper construction, or otherwise injure or delay the work or endanger adjacent structures. If the Engineer is of the opinion that at any point, sufficient or proper supports have not been provided, he may order additional supports put in at the expense of the contractor.

Dewatering of trench.

All pipes shall be laid on a solid, dry foundation. The contractor shall furnish all equipment, materials and labor necessary to keep all trenches free from water that is above or below ground. Any pipe laid in water or wet trenches will be removed and reinstalled at the contractor's expense.

The contractor shall provide, maintain, and operate such drains, percolation stone, trenches, sump pumps, hoses, piping, well- pointing systems, and other approved methods and equipment as may be necessary to keep the excavations free from water during all stages of the construction operations and course of work. The contractor shall provide such dikes, ditches, sumps and pumping equipment that may also be required to prevent the flow of surface waters into excavated areas and into any and all areas where construction or installations are in progress. All water pumped from the excavation shall be discharged in such a manner that shall not cause injury to work completed, damage to property, health hazards or pose an impediment to traffic.

Water shall be completely removed from all excavations promptly and continuously throughout the progress of the work, and the contractor shall keep excavations absolutely dry at all times until the water mains have been properly joined and bedded and work completed. Precautions shall be taken to protect uncompleted work from flooding during storms or from other causes.

Installation.

Care shall be taken not to injure the coating or lining when handling pipe, fittings, etc. and no smaller pieces or other materials of any kind shall be placed in the large pieces for transportation at any time. Any material found to have inherent defects upon delivery or to have been injured in transportation will be rejected.

All pipe, fittings, adapters, valves, and appurtenances shall be cleaned of foreign matter before being lowered into the trench and shall be kept clean during the laying operations by plugging or other approved means. Cutting of pipe shall be done in a neat and workmanlike manner with an approved type of mechanical cutter without damage to the pipe or lining so as to leave a smooth end at right angle to the axis of the pipe.

All joints of piping, couplings, fittings, valves, specials, and fire hydrants, whether push-on type or mechanical type, shall be made up in accordance with the manufacturer's printed recommendations.

Concrete thrust blocks shall be provided at all tees, bends, hydrants, and dead ends. Thrust block placement and size shall be as indicated on the standard detail "Thrust Blocks - Required Contract Bearing Areas" and/or on the plans.

The installation of tapping sleeves and valves for making wet taps under full main pressure shall be done only by workmen thoroughly experienced in this type of work. The existing main shall be thoroughly cleaned of all rust, dirt, scale or other materials down to the clean metal just prior to the installation of the tapping sleeve. Tapping connections shall be installed exactly horizontal and at right angles to the center line of the pipe to be tapped.

Gate valves and valve boxes shall be set plumb with a six-inch minimum base of broken stone or gravel. Valve boxes shall be centered on the gate valves and the box cover shall be set flush with the surface of the pavement or ground.

Hydrants shall be set plumb and to the established grade with hose nozzles at least 18 inches above the ground or as directed. A concrete thrust block shall be provided at each hydrant and one cubic foot of broken stone or gravel as indicated on the detail sheet.

(8)

Methods of construction for concrete encasement work shall conform to all applicable requirements of the American Concrete Institute Standards, ACI Standard 318.

(9)

At all areas where ductile iron pipe is exposed to corrosive soil condition, runs parallel to cathodically protected gas lines on the same side of the road or crosses gas lines, the water main shall be protected by encasing the pipe with plastic. Polyethylene film shall be applied loosely but continuously to the pipe with joints in plastic made by polyethylene adhesive tape. Care shall be taken in the installation and backfilling operation to prevent tearing the plastic and exposing the bare metal pipe.

Backfilling.

Unless otherwise approved by the Engineer, the contractor shall backfill all trenches at the end of each working day with suitable material from the trench excavation or temporary stockpile. Backfill shall be brought to elevations which allow construction of temporary paving specified elsewhere in these specifications. If, in the opinion of the Engineer, the above material is unsuitable, select off-tract material shall be provided. Backfill material shall be deposited and mechanically compacted to a minimum 90% modified proctor density in layers not exceeding six inches in depth (loose measure) to a point 12 inches above the top of the pipe. From this point, all backfill shall be mechanically compacted in maximum six-inch lifts, unless otherwise approved by the Engineer, to obtain a minimum 90% modified proctor density to a point three feet below the road surface. From this point, a minimum 95% modified proctor density is required. Smaller lifts shall be required if this density is not obtained. The backfill material shall be wet or dried as required to obtain the required density.

The only methods of compacting the backfill material permitted shall be mechanical compaction in lifts as specified. Consolidation will not be acceptable as a method to achieve the soil densities specified.

The Engineer, at his discretion, may perform, or have performed soil density checks at randomly chosen lifts. Density testing will be performed at the completion of the compaction effort. Compaction requirements will be strictly enforced.

When the trench is not in or across a dedicated street, right-of-way, or any other place where pavement is to be constructed, backfill shall be compacted to obtain a minimum 90% modified proctor density.

The densities referred to above shall be based upon the latest Standard Test Methods for Moisture-Density Relations of Soil and Soil Aggregate Mixtures Using 10 lb. Rammer and 18 inches" Drop, ASTM Designation D-1557. Density control in the field shall be based on the latest, ASTM Designation D-1556. The Township may retain and, except as otherwise specified, pay for the services of an independent testing laboratory from monies deposited in the developer's escrow account for inspection to do such sampling and to make such tests as the Township or Engineer may deem necessary to verify that work conforms to the requirements of the specifications.

Temporary pavement repairs.

During the interval between the completion of backfill and the time of placement of permanent paving, all pavement and drives shall be maintained in a safe and satisfactory condition. The contractor shall install all temporary pavement repair according to these specifications.

Temporary pavement repair shall be constructed within 24 hours of completion of backfill unless otherwise approved by the Engineer.

Temporary pavement repair shall consist of four inches minimum (compacted measure) of cold patch on all Township roads and six inches (compacted measure) of cold patch on county and state roads. Prior to placing the cold patch, the trench shall be thoroughly cleaned of all loose and foreign material. Cold patch shall not be applied when the surface is wet or dusty. Application shall be made only when the condition of the surface is acceptable to the Engineer.

The contractor shall continuously maintain temporary paving for the entire period it remains in place; shall inspect trenches at such intervals as may be necessary, including but not limited to; immediately following rainstorms, winter thaws, and similar occurrences which may cause settlement, erosion, or other problems; and shall promptly make necessary repairs to maintain trenches in a satisfactory condition. In the event the contractor fails to make such repairs, the Township may make such repairs as are deemed necessary and the contractor shall pay for the cost of this work. The contractor is required to repair all areas that are damaged by its actions during construction.

The Engineer, giving one week's notice, may direct the contractor to remove the cold patch surface and replace it with the permanent base course (hot mix asphalt base course).