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52081; RECYCLED WATER PHASE III PIPELINE EXPANSION; SUBMITTALS; 2015-02-09
01 TABLE OF CONTENTS .. Pipeline.................................................... ... .......................... .. ..... ... ............................ ......2 Vinlytech Purple C900 & C905 Pipe Master ........................ ................ ... ................ 3 Pvc C900 Stop Repair & Hd Couplings ............................................ ...................... ..6 Detectable Warning Tape......................................................................................... 11 ValvesAnd Fittings ........................................................... ............ ................................ 13 2-12in Afc 2500 Rw Gate Valve Master..................................... ........... . .............. .......14 Compact Push-on Short Form Spec ............. .......................................... ............ .19 Arivalves D-040 Combination 21 Accessories... .......................... ................................................. ................... ......................... .26 ltp Heavy Hex Bolt A307 B Zinc Plated ........................................................................27 Itp Non-asbestos Full Face 8th Inch Thick Gasket............................................. . .... ..29 Eisel411 Valve Box ............................................................................................. 31 Zinc Anode Northtown .......... ............. .................................. ............................... 33 Armorcast I 7x30 Box & Cover .............................................. ........... .................. 35 Armorcast A6000485sa Box And Cover ................ ............................................ .39 Sbf1243................................................................................................................41 Service Material ....................... .............................................................................. 43 Romac 202bs Service Saddles ............................................................................44 Ford Fb500-nl Mip Corp Ball Valve ................................................................. ....47 Ford Fb1100-7-q-nl ....................................... .............................. ..................... ....49 FordBfa43-777w-q-nl .......................................................................................... .51 FordFb1100-4-q-nl ...................................................................... ......................... 53 FordBa23-444w-nl ............................................................................................ 55. CopperPipe ....................................................................................................... ..57 -2- REPARED BY WESTERN WATER WORKS SUPPLY CO. -3- I Ll I h-, I I ' 'HE I I HE I NOMENISHl", IBM J PJ 11 P ITT 010 H ~ 171 ON 0 11 1) TA My Al [ % UU1 B M I MUT, Al Lip SCOPE These specifications designate the dimensional requirements for manufacturing and installing Vinyltech's Vinylguard Purple PVC Pipe for reclaimed water. AWWA C900-07 - Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 4 in. Through 12 in. (100mm Through 300mm), for Water Transmission and Distribution AWWA C905-97 - Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 14" Through 48" (350mm Through 1,200mm) for Water Distribution AWWA C605 - Underground Installation of Polyvinyl Chloride (PVC) Pressure Pipe and Fittings for Water ASTM D 1784 - Standard Specification for Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl Chloride) (CPVC) Compounds ASTM D 3139 - Standard Specification for Joints for Plastic Pressure Pipes Using Flexible Elastomeric Seals ASTM F 477 - Standard Specification for Elastomeric Seals (Gaskets ) for Joining Plastic Pipe ASTM P 2122- Standard Method of Determining Dimensions of Thermoplastic Pipe and Fittings ASTM D 2837 - Method for Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials PIPE COMPOUND The pipe shall be extruded from compounds meeting (PVC1120) the requirements of Cell Classification 12454, as defined in ASTM D 1784, Standard Specification for Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlori- nated Poly (Vinyl Chloride) (CPVC) Com- pounds. PIPE Vinyltech pipe shall be manufactured in accor- dance with the dimensional standards of AWWA C905 or AWWA C900. GASKET JOINT The gasket shall be reinforced with a steel band and meet the requirements of ASTM F 477. Vinyltech pipe shall have an integral bell end with a locked-in factory installed gasket and shall meet the joint requirements of ASTM D 3139. MARKING Vinylguard is marked with two print lines on oppo- site sides of the pipe. Both sides read "CAUTION RECLAIMED WATER - DO NOT DRINK" in intervals not to exceed 5 feet. Additional marking information is also applied. The UL, FM, and NSF designations do not apply and are not printed on reclaimed water pipes. QUALITY CONTROL Our full time quality assurance staff continually administers a rigid program of Vinyltech's standard tests to maintain the production of the best pipe products available. INSTALLATION Recommended installation procedure of Vinyltech Corporation and the Uni-Bell PVC Pipe Association are outlined in AWWA C605, Under- ground Installation of Polyvinyl Chloride (PVC) Pressure Pipe and Fittings for Water. The Uni- Bell Handbook of PVC Pipe is also an invaluable resource guide for design and installation. ASSEMBLING THE PIPE Assembly of Vinyltech purple PVC reclaimed water pipe is easily accomplished. A depth of entry mark is on each spigot end to serve as a visual check for rapid, accurate joint inspection. Do not over insert. Remove any mud, sand, or other foreign matter from the belled and spigot ends of the pipe. Carefully clean the gasket area. With a clean applicator (a brush or hand) lubricate the entire surface of the pipe from the spigot end to the depth of entry mark and the contact surface of the gasket with Vinyltech Brand Lubricant. Brace the bell to avoid disturbing the already installed joints. Align the pipe, insert the spig ot into the bell and push. Do not insert past the entry mark line. VINYLTECH :VA PVC • PIPE u-I PF~l EE E ( VINYLTECH 1111111 PVC-PIPE - 201 S. 61St Avenue Phoenix, AZ 85043 AN O1TERTA1LCOMPANY 602233-0071, 602 2724847 Fax www vtplpe corn -4- Effective 04/10 V1IIN M1 I MM EH IPUJRIE41IIIEI C900 DR 18 PRESSURE CLASS 235 1 NOMINAL SIZE (IN) (mm) OUTER DIAMETER (IN) MINIMUM WALL LFFTS PER TRUCK FEET PER LIFT APPROXIMATE WEIGHT (LB/lao') 4 (100) 4.80 0.267 16 . 1020 251.6 6 (150) . 6.90 0.383 16 440 521.2 8 (200) 9.05 0.503 20 200 903.0 10 (250) 11.10 0.617 12 240 1364.4 12 (500) 13.20 0.733 28 60-80 1935.8 C900 DR 14 PRESSURE CLASS 305 NOMINAL SIZE (IN) (mm) OUTER DIAMETER (IN) MINIMUM WALL LIFTS PER TRUCK FEET PER LIFT APPROXIMATE WEIGHT (LB/i 00') 4 (100) 4.80 0.343 16 1020 317.5 6 (150) 6.90 0.493 . 16 440 658.7 8 (200) 9.05 .0.646 20 .200 1139.7 10 (250) 11.10 0.793 12 240 1722.3 12 (500) 13.20 0.943 28 60-80 2445.5 C905 DR 25 PRESSURE RATED 165 NOMINAL SIZE (IN) (mm) OUTER DIAMETER (IN) MINIMUM WALL . LIFTS PER TRUCK FEET PER LIFT APPROXIMATE WEIGHT (LB/i 00') *14 (100) 15.30 0.612 120 1440 1935.0 16. (150) 17.40 . 0.696 40/60 . 1000 2575.0 18 (200) 19.50 0.780 40/60 1000 3165.0 *20 (250) 21.60 0.864 80 640 3900.0 *24 (300). 25.80 . 1.032 60 360 5600.0 C905 DR 18 PRESSURE RATED 235 NOMINAL SIZE (IN) (mm) OUTER DIAMETER (IN) MINIMUM WALL LIFTS PER TRUCK FEET PER LIFT APPROXIMATE WEIGHT (LB/i 00') *14 (100) 15.30 0.850 120 1440 2650.0 16 (150) 17.40 0.967 40/60 1000 3475.0 18 (200) 19.50 1.083 40/60 1000 4340.0 *20 (250) 21.60 1.200 80 640 5350.0 *24 (300) 25.80 1.433 60 360 7650.0 uortnern ripe rroaucts THE RIEBER SEALING SYSTEM The Rieber system provides a proven pipe joint with an excellent track record in the field. It is the fastest growing system in the world because of its many advantages. Factory installed, locked-in gasket The gasket is molded vs. extruded and spliced The pipe bell forms over the gasket, making a perfect fit Works equally well under pressure or vacuum Avoids the possibility of installing the wrong gasket Three sealing points achieved vs. two Reduces installation problems -- • LEAK-PROOF JOINTS The locked-in gasket eliminates gasket roll-out during joining "THE WORLDS BEST JOINT" . . vlNyLmcH JJ 201 S. 61st Avenue Phoenix, AZ 85043 . 01-rERT1ojI. Cof.NY PVC-PIPE 02 233-0071 • 602 27-87 • V - 5 PREPARED BY WESTERN WATER WORKS SUPPLY CO. -6- I- 11 • PVC Stop Couplings and Repair Couplings . .' . .. from CertainTeed offer a quick, simple solution to .$• . unwanted but necessary repairs or changes to existing f•'.,• (4'r I municipal water piping systems, and easy connection of short or cut lengths required in most piping installations. PVC Stop Couplings and Repair Couplings enable the installation or repair crew to remedy virtually all problems encountered in making tie-in connections. These two types of couplings allow the job to be completed quickly, so the piping system can be restored with minimal service disruption. PVC Stop Couplings and Repair Couplings supplied by CertainTeed are manufactured of extruded PVC coupling stock and are precision machined to exacting standards. Each Stop and Repair coupling is supplied complete with gaskets. For Cast Iron 0.13 pipe: Available in 4", 6" 8", 10" and 12" sizes in 200 psi working pressure rating. Couplings meet the requirements of AWWA Standard C900 for Municipal Water pipe, and comply with National Sanitation Foundation (NSF) Standard No. 61 for potable water service. Each coupling is hydrostatically tested to 800 psi, 4 times its rated working pressure of A1 - 200 psi. All sizes and classes are listed by Underwriters Laboratories Inc. (U/L). For IPS 0.13 pipe: Couplings are available in 11/2" through 12", are manufactured to meet ASTM 3139, and are listed by NSF for use with potable water. :4 9r.0 1 1111:4:-II Size Pipe O.D. Pressure Cplg Class(psi) O.D. P Mm. C insertion Depth Stop Coupling Part# Lbs. Weight I L Repair Coupling I Weight Part# Lbs. L 18-Long Coupling Repair Weight Part# Lbs. L 11 /2' 1.900 250 2.680 1 /8' 3.500 740206 0.90 7.063 742019 1.17 9.00 741012 2.95 18.0 2' 2.375 250 3.200 /32" 3.500 740213 1.20 7.188 742026 1.52 9.00 741029 3.81 18.0 2/2" 2.875 250 3.690 /I6" 3.500 740220 1.50 7.188 742033 1.86 9.00 741036 4.44 18.0 3.500 250 4.380 /4' 3.625 740237 1.90 7.313 742040 2.32 9.00 741043 5.76 18.0 4.500 250 5.470 /16" 3.625 740244 3.04 7.500 742064 3.38 9.00 741067 7.91 18.0 6" 6.625 250 7.840 1 /2' 3.875 740251 6.46 7.875 742088 6.50 9.00 741081 14.13 18.0 8" 8.625 250 10.190 /16" 4.000 740282 9.60 8.250 742095 10.17 9.00 741098 24.38 18.0 10' 10.750 200 12.438 /16" 4.250 740381 11.31 8.750 742101 14.25 11.50 741104 34.46 18.0 12" 12.750 200 14.648 /16' 4.375 740398 17.07 9.125 742118 21.5 12.00 741111 45.78 18.0 I Table I Cast Iron O.D. I Size C900 PVC Pipe 0.13 Pressure Class(psi) L Length P Insertion Depth Cplg. O.D. High Deflection (HD) Stop Coupling Weight Part # Lbs. Repair Coupling Part # Weight Lbs. 4 4.80 200 7.250 5/16 2/8 5.964 740718 4.00 742811 3.50 6" 6.90 200 8.250 5/16 3'/4 8.366 740725 8.24 742828 7.20 8" 9.05 200 9.250 11/16 3/ë 10.947 740732 15.62 742835 13.70 10" 11.10 200.*11.125 11/16 4/8 13.361 740749 27.45 742842 22.30 2" 13.20 200 12.000 11/16 5 15.836 740756 40.96 74283, '''"w jo. Table 2 Iron Pipe Size 0 D Average field conditions are assumed, and therefore the Engineer is the sole authority regarding actual installation specifications and procedures A Verify O.D. F Apply Lubricant Verify O.D. (Outside Diameter) of pipe Apply lubricant to the gasket surface that being jointed to be compatible (see Table 1 is exposed (never to the gasket groove) [CI O.D.] and Table 2 lIPS 0 D 1) and to the pipe spigot from the end of the pipe to the full insertion mark, especially Cutting to the rounded edge of the gasket and the When cutting pipe to be used with taper on the spigot In the case of repair couplings square cuts are essential When coupling use lubricate pipe entire distance making field cuts, it is best to use a PVC coupling will have to travel on pipe. Only pipe cutter to ensure square ends. A hand use lubricants supplied or approved by or power saw may be used if a pipe cutter CertainTeed. - is not available.warning Substances not specifically formulated for this purpose may Field. Beveling ' deteriorate pipe and/or gaskets. A bevel is required on the spigot end of the pipe being installed in the coupling G I Assembly of Stop Coupling The preferred method of beveling is using Push the spigot 'end into the coupling a PVC pipe beveling tool that is especially until it hits the stop in the coupling. The made for PVC Municipal Water pipe. .• full insertion mark on the pipe should be Hand tools like a coarse file or rasp can about flush with end of the coupling Use also be used to create bevel; refer- to . a bar and block if needed. A "come-along" Table 1 (CI O.D.) and Table 2 UPS O.D.) or puller may also be used, but be sure that for bevel dimensions. , . ' - the pipe and coupling are protected from the chains typically used with these types D. Clean Gasket and Spigot of devices. Stop couplings are used in areas Gaskets are shipped pre-assembled in the where a shorter than standard length of. couplings Using a rag wipe interior of pipe is required or when connecting to coupling and spigot end of pipe free of fittings hydrants etc.,and especially when all foreign materials. Note: If interior of ' a small bend is needed to change line or coupling gasket groove is dirty or-contains ' grade'. Each HD stop coupling is capable debris, carefully remove gasket and , of deflecting 5 degrees and can be used, thoroughly clean gasket groove in coupling'in place of small bends or where it is not and reinstall:the gasket. Make sure the flat desirable or possible to bend the barrel side of the gasket faces inside the coupling of the pipe. + and the rounded edge faces the coupling entrance. Make sure the gasket is evenly G-2. Damaged'Pipe Répáir sealed in the, groove by running your G-2A. Assembly of Repair Coupling finger all the way around, the inner face Push the spigot end into the coupling until of the gasket the spigot is up against the back side of the far gasket Align the other length of pipe E.. Full Insertion Mark - and slide the coupling back until the full Spigot end of pipe to be installed must . insertion mark on the pipe is flush with the , have a full insertion mark (refer to Table end of the coupling or not exposed. Use a l[a O.D.] and Table 2 [IPS O.DJ) put ' bar and block if, needed. A "come-along" on the pipe. This mark indicates when the , or puller may also be used, but be sure that pipe is fully inserted into the coupling, the pipe and coupling are protected from the chains typically used with these types of devices -9- G-2B. Assembly Where Two Repair - square cut and tapered, cleaned and well Couplings Required lubricated at least a distance equal to the Simply cut out and remove damaged area. length of the repair coupling being used. Make sure pipe ends are cut square and are Make sure the rpair coupling is clean, tapered. Clean pipe ends and lubricate well and lubricate the coupling's exposed ring for a distance equal to one half the length surfaces. Install both repair couplings on of the repair coupling being used. Make a the pipe by pushing each one onto the mark on pipe ends equal to one half the pipe until the spigot reaches the back of length of the repair coupling. the far gasket. Measure and cut a "Pup" joint approxi- Position the pipe with the repair couplings mately 21/2 to 3.1/2 inches shorter than he installed and push the couplings back over• distance between the two pipe ends being the existing pipe until the coupling edge is repaired. Both ends of the pipe must be about 3/4" short of the mark on the pipe; Example of Tie-in to Repair Existing System_ this will center the coupling over the gap. DamagedPipe JJjj Cut out damaged area jflf HE Pup joint and two closure/repair couplings F-11 I Slide closure/repair couplings onto pup joint until spigot reaches back side of far gasket I Insert into gap Iii 111111111111 liii_LIIIIIIIII11IlJIII Slide back closure/repair couplings flJJ jillltil High Deflection Coupling . . Each coupling is Bend Radius Chart (4' - 12") capable 01 uetuecung 5 degrees and can be used in pl ace of small bends, o where it is not desirable or possible to bend the barrel of the pipe. Pipe Length Mm. Radius with S per Coupling Deflection (no pipe bending) Offset per 20' Length 20 229 . 21" 10' .: 115 • 0:5 7.5' 86 8' 5' 57 5.25' ASK ABOUT OUR OTHER CERTAINTEED PRODUCTS AND SYSTEMS: EXTERIOR: ROOFING • SIDING • WINDOWS • FENCE • RAILING • TRIM.. DECKING • FOUNDATIONS • PIPE INTERIOR: INSULATION • WALLS •.CEILINGS -. CertainTeed Corporation Phone: 866-CT4-PIPE Pipe & Plastics Group Faxr 610-254-5428 .. . . . . . P.O. Box 860 wwwcertainteed.com CertainTeedll Valley Forge,PA 19482 . . . . •. . Code No. 40-904? © 5/07 Certaiiffeed Corporation Printed in U.SA • -10- Materials Detectable Warning TaDe Project Name Recycled Water Phase Ill Project Date:,Feb 09, 2015 Contractor Name Burtech Pipeline Water Agency Carlsbad Municipal Water District Spec Section COMMENTS: HYTECH detectable tape consists of a 5 mil overall thickness, with a .35 mu (.00035") solid aluminum foil core The construction is a 8 mil clear film, reverse printed with a repeating warning message and laminated to aluminum foil. with a 3.75 mil clear!ilrn backing. The lettering on all tapes is a minimum of 1" unless otherwise specified All tape is APWA color coded and permanently printed TFCHNICAIflATA PROPERTIES TEST METHOD VALUE Thickness ASTM D2103 0.005"(5 mil) Elongation ASTM D882-75B 80% Colors APWA Coded See Below. Tensile Strength ASTM D882 35 lbs/inch '(15,000 psi) Bond Strength, Boiling Water 5 Hours w/o Peel Adhesives Mfg.: Specs Morton 548 or Equivalent Bottom Layer Mfg. Specs Virgin LDPE (Polyethylene) Top Layer Mfg. Specs Virgin BOPP (Polypropylene) Foil Mfg. Specs .00035 Flexibility ASTM 671-76 Pliable Hand Message Repeat Mfg. Specs AXL II Inks Mfg Specs Varies per Legend Printability ASTM D2578 45 Dynes COLOR CODES Red - Electric, Fire Yellow - Gas, Oil Blue - Water, Potable Water Green - Sewer, Storm Drain Orana - Fiber Optic. Telojione I Purple - Reclaimed Water,INon-Potable Water. CUSTOM COLORS AND IMPRINTING AVAILABLE STOCK SIZES SIZE ROLL/CASE WEIGHT/ROLL 2"x 1000' 9 rolls/case 4.5 lbs per roll x 1000' 6 rolls/case 7 lbs per roll 1000' I 3 rolls/case 14 lbs ' per roll 12" x 1000' 1 roll/case 28 lbs per roll 800 WRAP-A-PIPE P.O. Box 2064 Huntington Beach CA 92647 714.897-0700 Fax 714 897-0600 -12- PHONE (909)597-7000 Start to Finish: FAX: (909)597-7050 People, Products, Systemi. SUBMITTAL DATA Materials: 2-12in AFC 2500 RW Gate Valve Master Project Name: Recycled Water Phase Ill Project Date: Feb 09, 2015 Contractor Name: Burtech Pipeline Water Agency: Carlsbad Municipal Water District Spec Section: COMMENTS: REPARED BY WESTERN WATER WORKS SUPPLY CO. -14- SERIES 2500 RESILIENT WEDGE GATE VALVE D AItZI 1 A SERIES 2500 RESILIENT WEDGE GATE VALVE RWGV I CONSTRUCTION UPPER 0-RING SEALS DUCTILE IRON OPERATING NUT can be replaced while the valve is provides strength and durability. fully open and under pressure. LOWER 0-RING SEAL seals lubrication chamber. -- THRUST WASHERS - minimize operating torque. HIGH-STRENGTH BRONZE STEM AND WEDGE NUT - resist corrosion and abuse. -. - r FUSION-BONDED-EPDXY COATING INSIDE AND OUT ensures maximum corrosion DUCTILE IRON CONSTRUCTION - resistance for long service life. Greater strength, durability, and lighter weight than cast gray iron construction. 250 p.s.i.g. AWWA UL & FM pressure rating. SMOOTH WATERWAY CONSTRUCTION - Oversize waterway. No recesses to trap debris or obstruct flow. Reduces pumping costs. -_ EPDM RUBBER-ENCAPSULATED DUCTILE IRON WEDGE -. ensures drop tight seal every time with low stem torque. - 1 -16- - SERIES 2500 RESILIENT WEDGE GATE VALVE RWGV I FEAT•URES/BENEFITS/SPECIFICATIONS FEATURES The Series 2500 Ductile Iron 250 exterior. The fusion-bonded coating is Thrust Washers p.s.i.g. AWWA Resilient Wedge Gate applied prior to assembly so that even Two thrust washers are used. One is Valve, is designed for use in drinking ,the bolt holes and body-to-bonnet located above, and one is located below water, sewage, and fire protection flange surfaces are fully epoxy coated. the thrust collar. These thrust washers systems as well as irrigation and Triple 0-Ring Stem Seals ensure easy operation at all times. backflow control systems. This valve features triple 0-Ring No Flat Gaskets Ductile Iron Construction stem seals. Two 0-Rings are located , The body-to-bonnet and bonnet- The ductile iron body, bonnet, above, and one 0-Ring is located to-bonnet'cover seals are pressure- and wedge provide strength and a below the thrust collar. The lower two energized 0-Rings. This eliminates pressure rating that meets or exceeds 0-Rings provide a permanently , the need for excessive bolt loading, the requirements of AWWA C515. sealed lubrication chamber that will ' which is required by designs that Strength more than doubles that make the valve easier to operate over use' flat gaskets. The 0-Rings are provided by cast gray iron designs, and a longer period of time. The upper reusable, which eliminates downtime the pressure rating is 250 p.s.i.g. All 0-Ring ensures that sand, dirt, or grit during-any needed repair. this strength and higher pressure rating cannot enter the valve to cause The Series 2500 Resilient Wedge is provided in a compact, lightweight, damage to the lower 0-Rings. This is Gate Valve is furnished in configurations and easy-to-handle ductile iron valve, especially important for buried and that are Listed by Underwriters Fusion-Bonded Epoxy sewage service applications. Laboratories, Inc. and Approved by The Series 2500 valve is fully , Factory Mutual Research Corp. - epoxy coated on the interior and the BENEFITS The Series 2500 Ductile Iron Resilient Wedge Gate Valve has these standard features: UL Listed-FM Approved 250 p.s.i.g. AWWA UL and FM Seat Tested at 500 p.s.i.g. Pressure Rating Fusion-Bonded-Epoxy Coating Rubber-Encapsulated Wedge Complies With ANSI/AWWA C550 Triple 0-Ring Stem Seals 250# Raised Face Flanges Thrust Washers Available Smooth (No Pocket) Waterway Ductile Iron Body, Bonnet, Wedge, 100% Leak-Tight Closure Operating Nut, and Stuffing Box NSF Standard 61 Certified Shell Tested at 500 p.s.i.g. , Complies with AWWA C515 SPECIFICATIONS Valves 2" 12" shall be resilient wedge type rated for 250 p.s.i.g. cold water working pressure. All ferrous components shall be ductile iron, ASTM A536. Valves 3"-12" shall be in full compliance with AWWA C515. The words "D.I." or "Ductile Iron" shall be cast on the valve. The wedge shall be ductile iron or bronze encapsulated with EPDM rubber. The wedge shall be symmetrical and seal equally well with flow in either direction. The gate valve stem and wedge nut shall be copper alloy in accordance with Section 4.4.5.1 of the AWWA C515 Standard. Stainless Steel stems are not acceptable. The NRS stem must have an integral thrust collar in accordance with Section 4.4.5.3 of AWWA C515 Standard. Two-piece stem collars are not acceptable. The wedge nut shall be independent of the wedge and held in place on three sides by the wedge to prevent possible misalignment. Valves shall be certified by NSF to Standard 61. Bolting materials shall develop the physical strength requirements of ASTM A307 and may have either regular square or hexagonal heads with dimensions conforming to ANSI B 18.2.1. Metric size socket head cap screws, therefore, are not allowed. The operating nut shall be constructed of ductile iron and shall have four flats at stem connection to ensure even input torque to the stem. All gaskets shall be pressure- energized 0-Rings. Stem shall be sealed by three 0-Rings. The top two 0-Rings shall be replaceable with valve fully open and while subject to full rated working pressure. 0-Rings set in a cartridge shall not be allowed. Valve shall have thrust washers located with (1) above and (1) below the thrust collar to ensure trouble- free operation of the valve. All internal and external surfaces of the valve body and bonnet shall have a fusion-bonded-epoxy coating, complying with ANSI/AWWA C550, applied electrostatically prior to assembly. Valves shall be American Flow Control's Series 2500 Ductile Iron Resilient Wedge Gate Valve. SERIES 2500 RESILIENT WEDGE GATE VALVE RWGV I DRAWING/DIMENSIONS SERIES 2500 - STANDARD NRS DIMENSIONS SUBMITTAL DATA 2"-12" SIZES ••T"r . WERITING NUT ri SHOWN WITH OPTIONAL HANOWHEEL - SHOWN WITH 2 OPERATING NUT See notes at bottom of page. DIMENSION ___________________________ VALVE SIZE Series 2500 Series 2500-1 2" 2-1/2" 3" 4" 6" 8" 10" 12" A 9.25 11.03 11.84 13.91 17.12 20.47 24.06 27.59 B 10.22 12.00 N/A N/A N/A N/A N/A N/A End to End - Mi/Mi 8.25 N/A 8.62 10.00 10.50 11.50 12.50 13.50 Lay Length - Mi/Mi 3.25 N/A 3.62 5.00 5.50 6.50 7.50 8.50 End to End -.FL/FL (Class 125) 7.00 7.50 8.00 9.00 10.50 11.50 13.00 1 14.00 End to End - FL/FL (Class 250) N/A N/A 11.12 12.00 15.88 16.50 18.00 19.75 End to End - TYITY N/A N/A N/A 13.00 15.88 17.50 18.75 19.75 End to End - Fl /Mi (Class 125) N/A N/A N/A 9.50 10.50 12.28 13.62 14.38 End to End - FLJTY (Class 125) N/A N/A N/A 11.00 13.19 14.50 15.88 16.88 End to End - PVC/PVC 10.75 11.12 11.38 13.00 15.88 17.50 N/A N/A End to End - Threaded 6.25 7.38 7.38 N/A N/A N/A N/A N/A Handwheel Diameter 8.06 8.00 8.00 10.00 12.00 14.00 15.50 15.50 No. of Turns to Open 1 9 1 11 13 14 20 - 26 32 38 3" through 12" valves meet or exceed requirements of ANSI/AWWA C515. 2-1/2" through 12" valves may be ordered in configurations which are UL Listed and/or FM Approved. 2" through 12" valves have 250 p.s.i.g. AWWA rated working pressure. 4.2-1/2" through 12" valves have 250 p.s.i.g. UL and FM rated working pressure. Fusion-bonded-epoxy coating meets or exceeds requirements of S ASME/AWWA C550. Flanged ends are in accordance with ANSI/AWWA Cl 10/A21.10 (ASME B16.1, Class 125). Threaded ends are in accordance with ASME B 16.4, Class 125. • Mechanical joint ends are in accordance with ANSI/AWWA Cli 1/A21.1 1. TytonH ends and push-on ends are in accordance with ANSI/AWWA Cli 1/A21.1 1 for use on cast iron (Cl) size ductile iron pipe. PVC ends are suitable for use on steel (I PS) sizes of PVC or steel pipe. 4" through 36" valves are certified to ANSI/NSF Standard 61. 12 It is recommended that stems be vertical in raw sewage applications QUANTITY 2" 2-1/2" 3" 4" 6" 8" 10" 12" L ______________ NRS with 2" Sq. Oper. Nut -. LI NRS with T-Head Oper. Nut U NRS with Handwheel U Post Indicator Valve (PIV) UOs&Y ACTUATOR (Check One) U NRS with Enclosed Miter Gearing Lj 2" Sq. Oper. Nut Parallel to Waterway LI 2" Sq. Oper. Nut Perpendicular to Waterway U Handwheel Perpendicular. to Waterway. Open Direction: U Left (C.C.W.) Q Right (C.W.) End Connections: Mechanical Joint Accessories: Q Yes U No UL Listed, FM Approved: U Yes Lj No Other Requirements (List on a separate sheet): PHONE (909)597-7000 I , Start to Finish: FAX: (909)597-7050 People, Products, Systems SUBMITTAL DATA, Materials Compact Push-On Short Form Spec Project Name: Recycled Water Phase Ill - Project Date: Feb 09, 2015 Contractor Name: Burtech Pipeline Water Agency: Carlsbad Municipal Water District Spec Section: COMMENTS: Compact Push-On Fithngs ANSI/AWWA C153/A21.53 4" - 24" DUCTILE IRON PUSH-ON JOINT COMPACT FITTINGS GENERAL SPECIFICATIONS MATERIAL: Ductile iron per ASTM A536 DDtEID. Cfi DCI -.H;.-.-. R..,. A" 'TA" D.--....., . 4.. .-._ .-...i.. .-...._ ..... ._...._... _. _. lugs ly IL)I - ' UIL. F I I32LiI IUIII i UJFJUOT IL) III III I) L)iiiY and UUD lvi UJJJIY IT.) iSlTUIlIIFi IUyS UT external restrainers TESTING: In accordance with ANSI/AWWA C153/A21.53 and UL requirements LAYING LENGTH: In accordance with ANSI/AWWA C153/A21.53 (fittings not listed in ANSI/AWWA have dimensions per Star design as noted in the catalog( WEIGHTS: Are in pounds, unless noted otherwise and do not include accessories, cement lining and coating FLANGES: Flanged ends on fittings match ANSI/AWW C115/A21.15 and ANSI B16.1 class 125 flanges CEMENT LINING: In accordance with ANSI/AWWA Cl 04121.4 - sizes 4"- 24" double thickness COATING: Asphaltic seal coat inside and out in accordance with ANSI/AWWA Cl 04/A21.4 GASKETS: Dual hardness SBR in accordance with ANSI/AWWA C1 1/A21.11 (see pg. 34( APPROVALS: 4"- 12" Underwriters Laboratories Listed 4" and greater are UL/NSF-61 DIMENSIONS: All dimensions are in inches unless noted otherwise AWWA MEMBER 718 DIA. 2 HOLES 71. DIA 2 HOLES 2 HOLIES 4-12" SIZES - - 14.24" SIZES - WATER QUALITY PUSH_-ON JOINT NOM. SIZE DIMENSIONS øA B.C.B C D 4 6.38 7.50 4.02 2.17 2.17 1.12 6 -. 8.52. 9.56 4.02 1.12 8 10.80 11.82 4.49 272 1.12 1.12 10 12.91 14.00 4.49 2.91 12 15.05 16.25 5.00 2.99 1.12 14 17.65 18.75 5.50 3.12 -- 3.25 3.25 1.25 16 19;81 21.00 5.50 5.50 1.25 1.25 18 22.11 23.25 20 24.23 25.50 30.00 5.50 3.28 1,;25 24 - 28.55 6.00 3.25 1.25 Please note: All fittings are standard with two (2) restraining tugs. Bends 451 & 901 in sizes 4" 12 are also available with four (4) restraining tugs. REV07 IS REGISTERED TRADEMARK OF STAR PIPE PRODUCTS FM STARS PIPE PRODUCTS HOUSTON CORPORATE ITOLL FREE 1-800-999-3009 [FAX 281-558-9000 wsw.sTaIpIpeproducts.corn Page 29 -20- 'REPARED BY WESTERN WATER WORKS SUPPLY CO. -21- è A. R. 1. FLOW CONTROL ACCESSORIES 40 tw Pr4 16 . - -WATER fSUPPLY Description phenomena: The D-040 Combination Air Valve has the features of both an - Impediment of effective flow and hydraulic conductivity of Air-release valve and an Air/vacuum valve. . the system along with a throttling effect . The Air-release component of the D-040 was designed to as would a partially closed valve. In extreme cases this will automatically release to the atmosphere small pockets of air as cause complete flow stoppage. they accumulate at local high points along a pipeline when the - Accelerate cavitation damages. pipeline or piping system is full and operating under pressure. - High pressure surges. The Air/vacuum component was designed to automatically - Accelerate corrosion of metal parts. discharge or admit large, volumes of air during the filling or -Danger of high-energy burst of compressed air. draining of a pipeline or piping system. This valve will open to - Inaccuracies in flow metering. relieve negative pressures whenever water.column separation . :- occurs. . As the system starts to fill, the valve functions according to the following stages: Applications Entrapped air is released by the valve - Pump stations: after the pump and after the check valve Liquid enters the valve, lifting the float which draws the "seal - After and before shut-off valve , , . ' plug" to its sealing position. - After deep-well pump '. .. , . 3. Entrapped air, which accumulates at peaks along the system - On long hydradlic gradient water supply lines ' ' (where combination air valves should be installed), rises to the - At peaks relatives to hydraulic gradient top of the valve, which in turn displaces the liquid in the valve's - At the end of lines . body. - Before water meter The float descends, peeling the "rolling seal", the smaller - On strainers orifice opens and the accumulated air is released. Liquid penetrates into the valve and the float rises unrolling Operation the rolling seal to its sealing position. The air & vacuum component, with the large orifice, discharges air at high flow rates during the filling of the system and admits When internal pressure falls below atmospheric pressure air into the system at high flow rates during its drainage. (negative pressure): High velocity air, cannot blow the float shut. water entry will Both orifices will be immediately unplugged and the float cause sealing of the valve, drops away. At any time during system operation, should internal pressure Air is admitted to the system. M of the system fall below atmospheric pressure, air will re-enter the systems. - Main Features - 0) The smooth release of air prevents pressure surges and other - Working pressure range: 0.2-16 bar (3-230 psi.) Testing pressure: destructive phenomena. 25 bar (360 psi.) Admitting air in response to negative pressure protects the - Working Temperature: 600 C - system from destructive vacuum conditions, prevents damage Maximum instantaneous working temperature: 900 C caused by water column separation. Air re-entry is essential to - Light, simple and reliable structure. efficiently drain the system. - Prevents premature closing: The automatic continuous acting component releases entrap - The valve discharges air at high velocity, exceeding 11 psi air from peaks of pressurized systems. - differential pressure. . Model one. way The D-040 air valve is available: D040-V -With a vacuum guarding, out-only attachment, which only allows air discharge, not allowing air intake (all models). D-040-I -With a vacuum breaking, In-only attachment, which only allows air intake, not allowing air discharge (D-040 2" only). D-040-NS -With a non-slam, discharge-throttling attachment, - which allows free air intake, but throttles air discharge (D-040 D-040 NS 2?? FL 4 e A.R.I. FLOW CONTROL ACCESSORIES . than in any other air release valve of it's kind, therefore it Project (tender): Specification discharges air at higher flow rates. Type Combination air valve - The size of the automatic orifice makes its obstruction by Operation debris most unlikely. -Kinetic component - The valve design - rolling seal mechanism: is less sensitive to The valve must discharge air at high velocity during filling of pressure differentials than a direct float seal. It accomplishes the system and admit air during its drainage. The valve should this by having a comparably large orifice for a wide pressure be designed to prevent premature closing and discharge air. range (up to 16 bar). -Automatic component - The body is made of high strength plastic, and all operating The valve will release accumulated air from the system while parts are made of specially selected corrosion resistant materials, it is under pressure and operating. - Due to its light weight, the valve may be installed on plastic Large dimension automatic orifice of at least 804 mm2 attached piping systems, as well as other lightweight piping. to the air & vacuum orifice making it less prone to obstruction - A threaded drainage outlet enables removal of excess fluids by debris. (11/211 in the 2,3/8" in the 3/4", 111) The same orifice for a wide pressure range (up to 16 bar). Pressure - 0.2-16 bar (3-230 psi) Valve Selection Testing pressure: 25 bar (360 psi.) The air valve is available: Ends 3/41 , 111, 2" male threads NPT, BSP. - With 3/411, 1", 2" male NPT, BSPT connections, as requested. Body material Reinforced nylon. - With a ball valve tap BSPT/NPT male connection upon request. Drainage outlets For easy removal of excess fluids. - Vacuum check - The valve is available as a valve that will only. - release air from the system and will not admit air to the system - when under pressure condition occur. This feature is accomplished by the addition of a check valve . inserted in the air outlet. ACCESSORIES . 4' Ball Valve Shut-off valve Made of brass ATSM B-124 Suitable for: D-040 1" 2", D-040-C 1" 2" Flanges Made of reinforced nylon / cast nylon . . ,, - . . Suitable for: D-040 1" 2" D-040-C 1" 2" 0-041 P 2. D-041-C.2 Diameter 40/50/60 Internal threads: 3/4" 1" 2" Diameter 40/50/65 Internal threads: 3/4" 1" 2" . . Diameter 80 Internal threads: 2" 3" 0-041 P 1" D-041 -C 1" K A Me FLOW CONTROL ACCESSORIES AIR AND1'/.X'i'1'J IFLOW 1 •!I j .' _iJ cc w. 0.6 . .......... -200,-100 0 -100 200 300 Flow Rate [m3/h] D-040 B 2" 0-040 ST 2" D-040 ST.ST. 2" PARTS LIST AND SPECIFICATION : AUTOMATIC AIR DISCHARGE No. Part Material Material 20 1" D-040 Pt B / ST D-040 ST ST - 1. Body Reinforced Nylon St.St. SAE 316 2 10 2. Drainage Elbow Polypropylene - Polypropylene 3. Seal Plug Assembly ... Screws Stainless Steel Stainless Steel 50 100 150 200 Plug Cover Reinforced Nylon Polypropylene Flow Rate [m3/h] Rolling Seal E.P.D.M. . Viton . . . . . . . . . Plug- Reinforced Nylon Polypropylene - A - 4. Clamping Stem Reinforced Nylon Polypropylene .5.- Float - - Foamed Polypropylene 0-Ring - BUNA-N Viton Base . Reinforced Nylon St.St. SAE 316 /Brass ASTMB124 / St.St. SAE 316 . Optional . - 5 - Ball valve- Brass ASTM B124 . B DIMENSIONS AND WEIGHTS Model r Dimensions m Weight Kg. ror1A• . - A B C Auto. Kin.I - . . A. 1", 1* D-040 P 100 143 /8" asP 0.33 - 7.8 100 • D-040 B 100 143 /8" asi' 0.33 , 7.8 100 D-040 ST. 100 143 /8" BSP F 0.33 .• 7.8 100 • . • D-040 ST.ST. 100 143 3/8" BSP I -. 4 7.8 100 - -.2" I - D-040-P I 180 209 11/2 13SP 1 1.1 12 804 B 4 C D-040-B 180 209 11/2" nsp 1 1.1 12 804 D-040-ST. I D-040ST.ST. 180 209 1'/2" BSP 1 1.1 320 1/2" asp' 12 804 .12804' b3a _ - - 6 -24 - p -- I INDUSTRIAL THREADED PRODUCTS INC. 13580 FIRESTONE BLVD., SANTA FE SPRINGS, CA 90670 800-976-BOLT FX: 800 646 4249 www.itpbolt.com •• NEAVYNEX BOLTS A301 GRADE 8 SUBMITTAL SPECIFICATIONS Abstract of ASTM A307 Grade B A307B • GRADE Low Carbon Steel 60,000 PSI CHEMICAL REQUIREMENTS Chemical analysis shall be performed in accordance with ASTM A751 CARBON MAX MANGANESE MAX PHOSPHOROUS MAX SULFER MAX 0.29 0.90 0.04 0.05 MECHANICAL REQUIREMENTS HARDNESS HARDNESS TENSILE ELONGATION BRINEL ROCKWELL STRENGTH IN 2 IN (50MM) MIN MAX MIN MAX MIN MAX MIN 121 212 69 95 60 100 18 Nn Heavy Hex Nuts ASTM A563 (ASME B18.2.2) Washers ASTM F844-90 BOLTS AND NUTS MAY BE SUPPLIED Plain Zinc Plated EJ Hot Dip Galvanized Blue Xylan LOCATION 91I Buried EJ Submerged EJ Above Grade EJ Below Grade EJ Other DIMENSIONAL DATA: Unless otherwise specified, threads shall be the coarse threaded series as specified in the latest issue of ANSI /ASME BI.1, page A-26. Having a class 2A tolerance. Grade B Bolts shall have Heavy Hex Bolt Dimensions as given in the latest issue of ANSI /ASME B 18.2.1, page Cl. Unless otherwise specified Grade B Bolts should be used with Heavy Hex Nuts. ADDITIONAL INFORMATION: Additional information can be found in ASTM A307 DTD 2001, ASTM A563, DTD 2001 12027 Arrow Route 8333Aijon Drive, Unit #C 16701 Stagg "A" 6474 Patterson Pass Road, UnitA 1832 G Street Rancho Cucamonga CA 90670 San Diego CA 92126 Van Nuys CA 91406 Livermore CA 94550 Fresno CA 93706 909-466-9445 858-635-5512 818-786-0916 800-566-8831 559-233-3026 1: 909-945-2696 fx: 858-635-5518 818-786-1620 ) fx: 800-6464249 • fx:559-233-2961 i INDUSTRIAL THREADED PRODUCTS INC... 13580 FIRESTONE BLVD., SANTA FE SPRINGS, CA 90670 800-976-BOLT FX: 800 646 4249 www.itpbolt.com NON-ASBESTOS GASKET SUBMITTAL SPECIFICATIONS GASKETS MEET THE PRESSURE RATINGS, DRILLING AND DIMENSIONS OF ANSI /ASME B16.2. I TECHNICAL DATA PRODUCT STYLE COLOR BINDER TEMP MAX PRESSURE MAX PRESS.X TEMP MAX COMPRESS. ASTM F-36 RECOVERY ASTM F-36. TENSILE STRENGTH ASTM F152 FLEXIBILITY CREEP RELAXATION ASTM F-78 KLINGER 4401 GREEN NBR 75d° 1400 PSI 400,000 7-17 50% 2000 PASSED 20 TEADIT NA 1001 GRN/WHT NBR 750° 1370 PSI 350,000 11 60% 1740 - 27 GARLOCK 1 3000 BLUE/GRN NBR 70b° 1000 PSI - 7-17 59.6% 2256 PASSED 24 AVAILABILITY 'FULLFACE El RING D 1/16" '4/8" D 1/4" SERVICE: Suitable against Air, Water, Brine, Sludge, Low Pressure Steam, Organic and Weak In-Organic Acids, Concentrated and Diluted Alkalis (PH Range From I to 11), Chemicals, Petroleum and Petroleum Derivatives, Synthetic Oils, Animals Fats, Vegetable Oils, Aromatic and Aliphatic Solvents, Chlorinated Solvents, and Refrigerants. These Gasket materials meet the pressure ratings, drilling and dimensional requirements of ANSI/ASME B16.2.1 andAWWAC207-94. . . . • GENERAL DESCRIPTION: Manufactured from a Non-Asbestos Material formulated for services in most sealing applications as a universal replacement gasket. The synthetic fiber content is Aramid Bound by Nitrile Rubber (NBR). These gaskets have a non-stick coating. 12027 Arrow Route 8333 Arjon Drive, Unit #C 16701 Stagg "A" 6474 Patterson Pass Road, Unit A 1832 G Street Rancho Cucamonga, CA 90670 San Diego, CA 92126 Van Nuys, CA 91406 Livermore, CA 94550, Fresno, CA 93706 909-466-9445 858-635-5512 818-786-0916 800-566-8831 559-233-3026 fx: 909-945-2696 . fx: 858-635-5518 fx: 818-786-1620 fx: 800-646-4249 . . : 559-233-2961 STANDARD VALVE BOX MARKINGS: IRWD •BLANK VI.WD SPECIAl. MARKINGS ON REQUEST STANDARD COVER MARKINGS: I ódaImedWater I Sewer Water SPECIAL MARKINGS ON REQUEST -32 - PHONE: (909)597-7000 t Start to Finish: FAX: (909)597-7050 People, Paducts, Systems SUBMITTAL DATA Materials: Zinc Anode Northtown Project Name: Recycled Water Phase Ill Project Date: Feb 09, 2015 Contractor Name: Burtech Pipeline Water Agency: Carlsbad Municipal Water District Spec Section: COMMENTS: PREPARED BY WESTERN WATER WORKS SUPPLY CO. -33- HYTECH PIPELINE PRODUCTS CATHODIC PROTECTION LINE PART # DIMENSIONS APPROX. WEIGHT CP-Z05 1.4'x 1.4"x 9" 5 lbs. CP-Z12 1.4'x 1.4"x 24" 12 lbs. CP-Z15 1.4"x 1.4"x30" 15 lbs. CP-Zj 2" x 2" x 18" 18 lbs. :1 CP-Z30 2" x 2" x 30" 30 lbs. I CP-Z45 2 x 2x 4 4 CP-Z80 2" x 2" x 60" 60 lbs. htflV nn..nt%flrr,..I _Ip1..,u I UMtJOJ I IUPI ASTM B-418-88 TYPE II BACKFILL COMPOSITION Zinc 99.980%(min) Gypsum 756/6 Aluminum .005% (max) Powdered Bentonite 20% Lead 003% (max) Anhydrous Sodium Sulfate 5% Iron .0014% (max) Copper .002% (max) LEAD WIRE Cadmium .003% (max) #12 THHN , #6 HMWPE , #8UF or as specified -34- U POLYMER CONCRETE I BOX A600164OPCX12 TOP VIEW OPEN BASE 19 1/4" 32 1/4" 16 1/8" 29 3/8" - 12" MOUSEHOLE ONE EACH END 17 1/4" 30 1/8" SECTION A SECTION 8-13 I Fn PART DESCRIPTION 30 Satic:y Street. North, Hollywood. CA 91605 17"x30"x12 POLYMER CONCRETE WATER METER BOX (818) 982-3600 CUSTWER ARMORQ1S® PRODUCTS cOMPANY WATER INDUSTRY 16. 166. I13-36 THE INFORMATION IN THIS DRAWING IS CONFIDENTIAL THE DRAWING IS NOT TO BE DRAWN DATE SCALE Mgx. LOAD REPRODUCED OR ITS CONTENTS DIVULGED AN ANY WAY WHATSOEVER ERCEPT WITH THE 3/98 NONE PRIOR WRITTEN APPROVAL OF ARMORCAST PRODUCTS COMPANY. IT IS THE PROPERTY APRQV. DRAWING NUMBER OF AND MUST BE RETURNED TO ARMORCAST PRODUCTS COMPANY, 13230 SAITCOY MATERIAL STREET, NORTH HOLLYWOOD, CALIFORNIA 91605. WS 3/98 POLYMER CONCRETE -36 - (ACCEPTS #A6000.482 DROP 'IN READ LID) 1 3230 Saticoy Street. AA North Hollywood, CA 91605 PART DESCRIPTiON 17"X 30" X 2" RPM COVER W/DROP-IN CAVITY C.~ (81,8) 982-3600 CUSTOMER WATER INDUSTRY #6. #66. 13-36 ARMORC4S\® PRODUCTS COMPANY THE INFORMATION IN THIS DRAWING IS CONFIDENTIAL THE DRAWING IS NOT TO BE DRAWN DATE SCALE MAX. LOAD REPRODUCE OR ITS CONTENTS DIVULGED IN ANY WAY WHATSOEVER EXCEPT WITH THE WS 3/98 NONE PEDESTRIAN PRIOR WRITTEN APPROVAL-OF ARMORCAST PRODUCTS COMPANY. IT IS THE PROPERTY OF AND -MUST BE RETURNED TO ARMORCAST PRODUCTS COMPANY, 13230 SAITCOY APROV. DR 3/98 MATERIAL DRAWING NUMBER STREET, NORTH HOLLYWOOD. CAIJFORNLA 91605. POLYMER CONCRETE -37 - POLYMER CONCRETE./ COVER A6.001643R. I N -ON SKID SURFACE 30 1/2" WA I METER I 73/4" 1 El 147/8" I 9 1/4" 17 1/2" I F~ - 13230 Saticoy Street. A North. Hollywood, CA 91605 PART DESCRIPTION 17"X 30" X 2" RPM COVER(818) W/RPM READ LID 982-3600 CUSTOMER ARMOR1S® PRODUCTS cOMPANY WATER INDUSTRY 46. #66. 13-36 THE INFORMATION IN THIS DRAWING IS CONFiDENTIAL THE DRAWING IS NOT TO BE REPRODUCED DR ITS CONTENTS DIVULGED IN ANY WAY WHATSOEVER EXCEPr- WITH THE DRAWN DR DATE 3/98 SCALE 1 NONE MAX. L AD PEDESTRIAN PRIOR WRITTEN APPROVAL-OF ARMORCAST PRODUCTS COMPANY. IT IS-ThE-PROPERTY DT AND MUST BE RETURNED TO ARMORCAST PRODUCTSCOMPANY, 13230 SAI1COY STREET, NORTH HOLLYWOOD, CAIJEORNIA 91605. APROV. WS 3/98 MATERIAL POLYMER CONCRETE DRAWING NUMBER -38- Aga WATER METER BOXES & COVERS 4RMORCdS to ARMORCASTIPRODUCTS CO ! I' POLYMER CONCRETE COVER with <- 6 COVERS HINGED READER LID COVER with DROP-IN LID COVER SIZE 9" x 14" [mD1$ 3 B-3 II]IJ±1II --- YTj --- ]1J!ffJ --- TI --- h[I]J •TA!j --- --- I]IJ;ffJ YjTU Drop-In Part# Size! --- 10"X15" 36,3.5 B-9 A6001922R 13 lbs.A6001922TR 18 lbs. A6001922DQ 10 lbs. A6001922TD0 16 lbs. A6000487T 5"x 10" x 20" 33,4 --- A6000483R 15 lbs. A6000483TR 19 lbs. A6000483DQ 13 lbs. A6000483TDQ 16 lbs. A6000487T 5"x 11"x21" 8-16 A6000489R 23 lbs. A6000489TR 26 lbs. --- --- --- x 18" --- A6001428R 15 lbs. A6001428TR 16 lbs. --- --- --- x18" A6001426R 19 lbs. A60014261R 20 lbs. --- --- --- 12" x 20" 37, 4.5 B712 A6000484R 17 lbs. A6000484TR 23 lbs. A6000484DQ 13 lbs. A6000484T0Q 19 lbs. A6000487T 5"x 13" x 24" 38, 5.25 B-30 A6001866R 35 lbs. A6001969TR 37 lbs. A60018660Q 34 lbs. A6001866TDQ 37 lbs. A6000487T 5"x 17" x28" 65, 5.5 A6001420R 29 lbs. A6001420TR 45 lbs. A6001420DW 29 lbs. A600142OTDW 42 lbs. A6000481DT 7"x1: 17" x30" 66,6 B36 A6001643R 45 lbs. A6001947TR 69 lbs. A6001643DZ 45 lbs. A6001643TDZ 65 lbs. A60004821 9"x 1 18" x 19" --- B-24 A6000491R 30 lbs. A6000491TR 42 lbs. A000491DW 25 lbs. A6000491TDW 25 lbs. A6000481DT 7" xl: 24" x 36" 67 8-40 A6001975R 102 lbs. A6001975TR 104 lbs. A6001975DZ 85 lbs..,A6001975TDZ 85 lbs. A6000482T 9"X 1. 30" x 48" 68 B-48 --- --- --- --- A6001470DZ 86 lbs. A600147OTDZ 86 lbs. A6000482T 9" X 1 Contact an Armorcast Products Company representative for more information and technical assistance on our products and capabilities. WATER METER BOXES :!sX41PA x 14" x 12" INDUSTRY REFERENCE [s1i[.lIete irIT 1:iefer iir. 3 B-3 STRAIGHT WALL POLYMER CONCRETE --- (Ii WEIGHT FLARED W POLYMER A6000494 LL 1PT I II.) 39 lbs. 10" xiS" x 12" 36,3.5 8-9 --- --- A6001921X12 46 lbs. 10" x 20" x 12" 33,4 --- A6000486 34 lbs. A6000486SA 38 lbs. 11"x21"x12" --- B-16 A6000492 51 lbs. 11" x18" x 12" --- A6001429 33 lbs. 12" x 18" x 12' --- A6001425 41 lbs. 12" x 20" x 12' 37, 4.5 B-12 A6000485 33 lbs. A6000485SA 38 lbs. 13" x 24" x 12" 38, 5.25 B-30 A6001946PCX12 50 lbs. 17"x28"x12" 65,5.5 A6001419 55 lbs. A6001419SA 78 lbs. 17" x 30" x 12" / 18" 66,6 B-36 A6001640PCX12/18 701b5./961b5. 18" x 19" x 12" --- B-24 A6000490 60 lbs. --- 24"x 36" x 12"/ 18" 67 B-40 A6001974PCX12 / 18 100 lbs. / 147 lbs.. 30" x 48" x 18" 68 B-48 A6001430PCX18 192 lbs. --- OTHER SIZES & DEPTHS ARE AVAILABLE. Contact an Armorcast Products Company representative for more information and technical assistance on our products and capabilities. YYAY&YAYiR1iiits]f*MrnTi!i(S]ii Tel: (818) 982-3600 Fax: (818) 982-7742 5 -40- 0 2013 Armorcast Products Company 0313 PREPARED BY WESTERN WATER WORKS SUPPLY CO. -41- SEWER CLEANOUT South Bay. Foundry, In.E OR VALVE BOX 9444 Abraham Way • Santee, Ca. 92071 • Ph. 619-956-2780 : ......T 895.s: Inland Center Dr. • San Bernardino, Ca. 92406 • Ph. 909-888-3334 B6 42 No. Cluff Ave. • Lodi, Ca. 95240 • Ph. 209-367-1940 -42 - ROMAC INDUSTRIES, INC. STYLE 10113S & 202B5 BRASS SERVICE SADDLE WITH STAINLESS STEEL NUTS, BOLTS AND STRAP SUBMITTAL INFORMATION MATERIALS Casting The saddlebody is cast from 85-5-5-5 waterworks bronze in accordance with AWWA C800 and ASTM B 62. Gaskets Gaskets are made from Nitrile Butadiene Rubber (N BR) compounded for water and sewer service and a • tolerance of petroleum products in accordance with ASTM D 2000 MBC 610. Other compounds available for special applications Straps Type.304 (18-8) heavy gauge Stainless Steel per ASTM A 240. Straps are twoinches wide to spread out clamping forces on the pipe GMAW and GTAW welds Passivated for corrosion resistance Bolts, Nuts 5/8" UNC roll thread Type 304 (18-8) Stainless Steel bolts per ASTM A 479. Heavy hex nuts per ASTM A 194. All welds fully passivated for enhanced corrosion resistance. Nuts coated to prevent galling. Washers Flat, type 304 (18-8) heavy gauge Stainless Steel. PRESSURE. When properly installed on a pipe that is within the correct outside diameter range, the Romac Bronze Style service saddles can be used at working pressures up to 200 psi. SIZES AND RANGES See Catalog. I, Romac Document Number 25-8-0005 • QIfl This information is based on the best data available at the date printed above, please check with Romac Engineering Department for any updates or changes Phone4425)051 62GO Toll Free 1 800 420 9341 ' Fax 425) 551 0201 'www, rnac Idtstvks oo 44 -45- ••• • BRONZE SINGLE STRAP SERVICE SADDLES BRONZE DOUBLE STRAP SERVICE SADDLES NOW "h' & 1' I.P. Or CC• APPROX IAF "i.' & 1" IRar C.C. I W, 1'!?, 2" LP. C.C. PPR0X. PSEE IPE O.D.PIPE RANGE 101 1O1 BS ¶T 202B 2028S 202B 202BS W 4.50 -14.80 N/A $188.621 $166.20 $233.55 $193.88 8.o# 4" 4.50-5.40:. $112.67 $9187 4.0 t N/A - 480-540 N/A 18862 16620 23355 19388 80# 600-663 13426 475# N/A en 1_2 6.63 -7.50 134.28 111.49 4.75 # 234.39 J 195.81 f 238.37 84 9.0# 800-863 14093 14211 50# N/A 8" 863 962 14093 2 142 .11, 50 # 26830 24232 27229 255.12 11.5 # 1000-1075 18435 18590 75# 31413 30024 31814 32980 110# 11.10-12.12 . 184.35 185.90 7.5# 314.13 300.24 318.14., 329.80 11.0# 12.00 - 12.75 1 196.33 197.96 9.0 # I 330.87 333.81 352.20 376.58 12.0 # 13.20-:14.38. 196.33 197.96 9.0 # 330.87 333.81 352.20 378.56 12.0 # 14" 1440 1600 N/A 36395 370.79.388651 42064 130# 1611 1600-1740 41777 44245 45450 ' 49633 150# 1732-1745 41777 44245 45450 49833 150# When ordering for PVC pipe, specify 0.D. (DI or UPS) - 'All saddles to be used on IPS size PVC must use stainless steel strap for bronze saddles 2f4ot recommended for IPS size PVC. Saddles for ductile iron size PVC (C-900), Iron pipe size PVC and copper should be preformed at factory. To Order: Add tap size to the upper range of the saddle. STYLE UPPER TAP TYPE RANGE SIZE THREAD Example: Bronze Saddle with Bronze Strap ('B"): 111011B - 7.50 x III" Bronze Saddle with Stainless Steel Strap ('BS") 1 10108 7.50 x W' UP -46- S . Materials Ford FB500-NL MIP Corp Ball Valve Project Name: Recycled Water Phase Ill Project Date Feb 09 2015 Contractor Name: Burtech Pipeline Water Agency Carlsbad Municipal Water District Spec Section: COMMENTS: SUBMITTAL INFORMATION 1I\\I'I V ri 111111111111 Ballcorp Corporation Stops - (FB500-x-NL style) MALE IRON PIPE THREAD BOTH ENDS Solid one piece tee-head and stem Molded EPDM rubber seats support the ball EPDM 0-ring in the stem Male Iron Pipe " MIP Outlet Threads Inlet - ___________ - - + - - - - - Outlet Fluorocarbon-coated brass ball Length SIZE INLET SIZE OUTLET SIZE VALVE LENGTH BODY OUTLET THREADS / SUBMITTEDVALVE APPROX. WT. LBS PART NUMBER ITEM(S) 3/40 3/40 3/4° 4-5/16 3/4° MIP 1.4 FB500-3-NL 1° 1' 11.4-15/32 11, MIP 2.0 FB500-4-NL 1-1/4" 1-1/4 1-1/4 5-5/8 11/4u MIP 4.0 FB500-5-NL 1-1/2" 1-1/2 1-1/2 6-11/16" 1-1/2" MIP 5.4 FB500-6-NL 2° 2° 20 7-3/16 2° MIP 7.9 FB500-7-NL WITThOUAUIY FEATURES All brass that comes in contact with potable water conforms to AWWA Standard C800 (UNS NO C89833) Brass components that do not come in contact with potable water conform to AWWA Standard C800 (ASTM B-62 and ASTM B-584, UNS NO C83600 - 85-5-5-5) The product has the letters "NL" cast into the main body for proper identification UL Classified to ANSI/NSF Standard 61 Ends are integral or secured with adhesive to prevent unintentional disassembly 300 PSI working pressure The Ford Meter Box Company considers the information in this submittal form to be correct at the time of publication. Item and option availability, including specifications, are subject to change without notice. Please verify that your product information is current. The Ford Meter Box Company, Inc. Submitted By: I I P.O. Box 443, Wabash, Indiana U.S.A. 46992-0443 Phone: 260-563-3171 / Fax: 800-826-3487 Overseas Fax: 260-563-0167 http://www.fordmeterbox.com 08/03/09 -48- 4$4 TdA144 PHONE: (909)597-7000 Start to Finish: FAX: (909)597-7050 People, Products, System SUBMITTAL DATA: Materials: Ford FBII00-7-Q-NL Project Name: Recycled Water Phase Ill Project Date: Feb 09, 2015 Contractor Name: Burtech Pipeline Water Agency:• Carlsbad Municipal Water District Spec Section: COMMENTS: MALE IRON PIPE THREAD INLET BY QUICK JOINT FOR COPPER OR PLASTIC TUBING (CTS) OUTLET Molded EPDM rubber seat supports the ball Body Outlet Threads Solid one piece tee-head and stem EPDM 0-rings in the stem.,Quick Joint Nut Male Iron Pipe Threads Stainless Steel Gripper. Inlet Outlet /7, //•/' / \ / Molded Buna-N Spring Tip Gasket provides Hydraulic Seal External Nut Stop Length Fluorocarbon-coated brass ball VA V S IN ET S OUTLET VALVE BODY OUTLET APPROX. L E iZE L iZE PART / SUBMiI-rED SIZE LENGTH THREADS I WT. Los NUMBER ITEM(S) 2 2" 2" 7-1/16 2" Special Thread 1 7.9 F81100-7-Q-NL Note: Ford recommends using insert stiffeners with plastic pipe or tubing. FEATURES All brass that comes in contact with potable water conforms to AWWA Standard C800 (UNS NO C89833) The product has the letters "NIL" cast into the main body for proper identification UL Classified to ANSI/NSF Standard 61 and Standard 61 Annex G (NSF/ANSI 372) Brass components that do not come in contact with potable water conform to AWWA Standard C800 (ASTM B-62 and ASTM B-584, UNS NO C83600 - 85-5-5-5) Ends are integral or secured with adhesive to prevent unintentional disassembly 300 PSI working pressure The Ford Meter Box Company considers the information in this submittal form to be correct at the time of publication. Item and option availability, including specifications are subject to change without notice Please verify that your product information is current The Ford Meter Box Company, Inc. SUbmitted By: ' P.O.Box 443 Wabash Indiana USA 469920443 Phone: 260-563-3171 / Fax: 800-826-3487 -50 - Materials Ford BFA43-777W-Q-NL Project Name Recycled Water Phase Ill Project Date: Feb 09, 2015 Contractor Name: Burtech Pipeline Water Agency Carlsbad Municipal Water District Spec Section: COMMENTS: PREPARED BY WESTERN WATER WORKS SUPPLY CO. -51- QUICK JOINT FOR COPPER OR PLASTIC TUBING (CTS) INLET BY METER FLANGE OUTLET I Solid one piece tee-head and stem Padlock Wing Sturdy stops allow 90 motion and / ' A snap ring locks the stem are enclosed and protected. ',',, into the body of the valve EPDM 07-rings in the stem. ' Molded EPDM rubber K ',',' seat supports the ball Meter Flange Fluorocarbon coated brass ball - —Outlet External Nut Stop \ \ N .- Molded Buna-N Spring Tip Gasket Height Provides Hydraulic Seal Stainless Steel Gripper Quick Joint Nut - "(.3 k—lnlet -30 'I Length — .. VALVE SIZE SERVICE LINE METER SIZE LENGTH HEIGHT APPROX. PART Size INLET OUTLET WT. LB S NUMBER- 2" 2 .2' 2-13/16" 3-5/8 9.1 BFA43-777W-Q-N Note: Ford recommends using insert stiffeners with plastic pipe or tubing. / SUBMITTED FEATURES All brass that comes in contact with potable water conforms to AWWA Standard C800 (UNS NO C89833) . . Brass components that do not come in contact with potable water conform to AWWA Standard C800 (ASTM B-62 and ASTM -B-584, UNS NO C83600 - 85-5-5-5) The product has the letters "NL" cast into the main body for proper identification UL Classified to ANSI/NSF Standard 61 and Annex G Padlock Wing for locking valve in closed position Hole for attaching handle is provided in the tee head 300 PSI working pressure Includes EPDM drop-in style meter gasket Suitable for customer side shut off (outlet side of meter) up to 300 PSI Slotted holes are standard on 2" Flanged Meter Valves, allowing 11/2i Flange Meter. connection Optional: Full 3600 tee head rotation. Insert "R" into the part number. Example: BFA43-777WR-Q-NL Meter support brackets Insert -MSB Into the part number Example BFA43-777W-MSB-Q-NL I he Ford Meter Box Company considers the information in this submittal form to be correct at the time of publication. Item and option availability, including specifications, are subject to change without notice. Please verify that your product information is current. The Ford Meter Box Company, Inc.- Submitted By: . . P.O.Box 443 Wabash Indiana USA 469920443 Phone: 260-563-3171 I Fax: 800-826-3487 -52 - PREPARED BY WESTERN WATER WORKS SUPPLY CO. -53 - MALE IRON PIPE THREAD INLET BY QUICK JOINT FOR COPPER OR PLASTIC TUBING (CTS) OUTLET Molded EPDM rubber seat supports the ball Body Outlet Threads Solid one piece tee-head and stem,,,,, - EPDM 0-rings in the stem Quick Joint Nut Male Iron Pipe Threads ". ":'\,":•' S S Stainless Steel Gripper Inlet Outlet Molded Buna N Spring Tip Gasket provides Hydraulic Seal External Nut Stop Length Fluorocarbon-coated brass ball Note: Ford recommends using insert stiffeners with plastic pipe or tubing. FEATURES All brass that comes in contact with potable water conforms to AWWA Standard C800 (UNS NO C89833) The product has the letters "NL" cast Into the main body for proper identification UL Classified to ANSI/NSF Standard 61 and Standard 61 Annex G (NSF/ANSI 372) Brass components that do not come in contact with potable water conform to AWWA Standard C800 (ASTM B-62 and ASTM B-584, UNS NO C83600 - 85-5-5-5) Ends are integral or secured with adhesive to prevent unintentional disassembly 300 PSI working pressure The Ford Meter Box Company considers the information in this submittal form to be correct at the time of publication. Item and option availability, including specifications, are subject to change without notice. Please verify that your product information is current. The Ford Meter Box Company, Inc. Submitted By: I P.O.Box 443 Wabash Indiana USA 469920443 Phone: 260-563-3171 / Fax: 800-826-3487 VALVE SizE IN INLET SIZE OUTLET VALVE BODY OUTLET APPROX. PART / SUBMITTED Size LENGTH THREADS WT. LBS NUMBER ITEM(S) 1" 1" 1" 4-13/64" 1" Flare Copper 2.7 FB1100-4-Q-NL 1' 1" 1-1/4" 4--9116" 1-1/4" Flare Copper 3.2 FB1100-45-Q-NL -54- -55- FLARE COPPER INLET BY METER SWIVEL NUT OUTLET Solid one piece tee-head and stem A snap ring locks the stem into Padlock Wing for locking valve the body of the valve in closed position '- - '. -'/ ., Bronze Snap Ring EPDM 0-rings in the stem -- Meter Swivel Nut Fluorocarbon-coated Meter Gasket (EPDM) f —Meter Coupling Thread Molded EPDM rubber - Height seat supports the ball Flare Copper Nut SERVICE LINE VALVE SIZE SIZE INLET All V. 1k -*1 Inlet METER SIZE APPROX. - PART LENGTH HEIGHT -OuTLET WT. LBS I NUMBER 1" 2-29/64 24/A4 S RA9.AAdW. / SUBMITTED ITEM(S) () WII!R OUAIUY FEATURES All brass that comes in contact with potable water conforms to AWWA Standard. C800 (UNS NO C89833) Brass components that do not come in contact with potable water conform to AWWA Standard C800 (ASTM B-62 and ASTM B-584, UNS NO C83600 - 85-5-5-5) The product has the letters "NL" cast into the main body for proper identification UL Classified to ANSI/NSF Standard 61 and Annex G Ends are integral or secured with adhesive to prevent unintentional disassembly Hole for attaching handle is provided in tee-head 300 PSI working pressure Padlock Wing for locking valve in closed position Meter nut drilled for seal wire Note: Recommended for inlet side shut-off Optional full 3600 tee-head rotation. Add "R" to end of part number I he Ford Meter Box Company considers the information in this submittal form to be correct at the time of publication. Item and option availability, including specifications, are subject to change without notice. Please verify that your product information is current. The Ford Meter Box Company, Inc. Submitted By: ii P.O.Box 443, Wabash Indiana U.S.A.469920443 Phone: 260-563-3171 I Fax: 800-826-3487 Overseas Fax: 260-563-0167 - - http://www.fordmeterbox.com 12/13/10 - -56- 'u' CAMBRIDGE-LEE INDUSTRIES, LLC. SA Reading Tube Division P.O. Box 14026, Reading, PA 19612 -4026 Phone 610 -9264141 Fax610-9267317 Distributor: A Customer: Address: Address: Order No.: P.O. No.: Product: Standard Tube Certificate of Conformance Tube Type Specification No. Specification Title ASTM B 88 Standard Specification for Seamless Copper Water Tube Type K,L&M NSF 61 ANSI/NSF Standard 61 Drinking Water System Components Health Effects': - Coils and Straight Lengths Marked as ASTM B 280 Standard Specification for Seamless Copper Tube for Air Conditioning and ACR Refrigeration Field Service Type DWV Drainage ASTM B 306 Standard Specification for Copper Drainage Tube (DWV) Type K & LStraight Lengths Marked as OXY/MED ASTM B 819 Standard Specification for Seamless Copper Tube for Medical Gas Systems Cambridge-Lee Industries, LLC, located in Reading, PA, USA, manufactures seamless copper tubing in the United States of America and is fully compliant with the "Buy American" requirements of Public Law 111-5, the American Recovery and Investment Act of 2009. Cambridge-Lee Industries, LLC, manufactures seamless copper tubing with recycled scrap. Our production meets the LEED, Leadership in Energy and Environmental Design qualifications. The process of scrap recycling entails the purchase of# 1 grade scrap and converting it in a finished cast form, which meets specification; alloy C 12200, for standard product production. Currently, operations purchases about 65% of #I scrap. The remaining capacity is cathode copper and run around. Cambridge-Lee Industries, LLC certifies that the copper tube manufactured is grade UNS C 12200 and meets the applicable chemical, mechanical, cleanness and eddy current testing requirements of the current specification(s) indicated above. When specified at order placement and for an additional cost, CLI - RTD can supply product mill test reports of the current ASTM standard. Copper tube manufactured by Cambridge-Lee Industries does not contain mercury or come in contact with mercury, mercury compounds or mercury containing devices at any stage in manufacturing, inspection, packaging or shipping. All of the specifications require a minimum copper plus silver content of 99.9% and phosphorus content between .015 -.040%. As indicated by the compositional requirements, the copper tube is essentially lead free. NSF Standard 61 Restriction Statement: "Seamless Copper Tube (Alloy C12200) is certified by NSF to NSF/ANSI Standard 61 for public water supplies meeting, or in process of meeting the U.S. EPA Lead and Copper Rule (56FR 26460, June 7, 1991). Water Supplies with pH less than 6.5 may require corrosion control to limit copper solubility in drinking water." Some water supplies may be corrosive to copper and in these cases water treatment may be necessary. F-0225 rev .6, -58- BLUE BRUTETM! BIG BLUET7ULTRA BLUETM JM agIe AWWA C900/0905/0909 ASTM F1483 INSTALLATION GUIDE for Building essentials a better tomorrow RUPTURE HAZARD IMPROPER INSTALLATION OR MISUSE OF TAPPING TOOLS MAY CAUSE PIPES UNDER HIGH PRESSURE TO RUPTURE AND RESULT IN HIGH VELOCITY AIRBORNE FRAGMENTATION LEADING TO SERIOUS INJURIES. BEFORE AND DURING INSTALLATION, ALWAYS: CONSULT AND FOLLOW THE FULL VERSION OF THE PRODUCT INSTALLATION GUIDE CLOSELY FOLLOW JOB SPECIFICATIONS USE PROTECTIVE GEAR AND EQUIPMENT • BEFORE AND DURING TAPPING, ALWAYS: CONSULT AND FOLLOW UNI-BELL° PUBLICATION UNI-PUB-08-07, "TAPPING GUIDE FOR PVC PRESSURE PIPE." USE THE CORRECT TAPPING TOOLS BLEED AIR FROM PIPES AT HIGH SPOT BEFORE TAPPING USE PROTECTIVE GEAR AND EQUIPMENT PLEASE CONTACT JM EAGLE" PRODUCT ASSURANCE AT (800) 62174404 TO OBTAIN FULL VERSION OF THE APPROPRIATE INSTALLATION GUIDE OR FOR FURTHER ASSISTANCE. BLUE BRUTE TM/ BIG BLUE TM/ ULTRA BLUE TM CONTENTS 1.0 RECEIVING AND HANDLING PIPE SHIPMENTS ....................8 1.1 INSPECTION .............................................8 1.2 UNLOADING .............................................9 1.3 COLD WEATHER HANDLING .................................11 1.4 STOCKPILES .............................................11 1.5 GASKET CARE ..........................................12 1.6 LOADING TRANSFER TRUCKS .............................12 1.7 DISTRIBUTING ALONG THE TRENCH ........................13 2.0 TRENCH CONSTRUCTION ...................................13 2.1 WORKING AHEAD OF THE PIPE LAYING CREW ................13 2.2 CURVES IN THE TRENCH ...................................14 2.2.1 BLUE BRUTE'TM AWWA 0900 AND ULTRA BLUE AWWA C909 (4-16") 14 2.2.2 BIG BLUE' AWWA 0905 (14-48") ......................15 2.3 TRENCH WIDTHS ........................................16 2.4 TRENCH DEPTHS ........................................17 2.5 PLANNING FOR THRUSTING ...............................17 2.6 PREPARATION OF TRENCH BOTTOM ........................18 2.7 CASINGS ...............................................18 2.7.1 PLACEMENT OF CASINGS ...........................18 2.7.2 PULLING THE PIPE ..................................19 2.7.3 CLOSURE OF CASING AFTER PIPE INSTALLATION .......21 3.0 PIPELINE CONSTRUCTION ..................................23 31 INSPECTION ...........................................23 3.2 LOWERING PIPE AND ACCESSORIES INTO TRENCH ..........23 3.3 ASSEMBLY OF JM EAGLET' PVC PIPE .......................24 3.4 ASSEMBLY INSTRUCTIONS ................................24 3.5 CUTTING ..............................................27 3.6 BEVELING .............................................28 3.7 LOCATING REFERENCE MARK ............................28 3.8 ASSEMBLY AT FITTINGS AND ADAPTORS ...................28 3.9 THRUST BLOCKING AND ANCHORAGE AT FITTINGS ..........29 3.9.1 DETERMINING SIZE AND TYPE OF THRUST BLOCKING . . .29 3.9.2 UPWARD THRUSTS AT FITTINGS .....................32 3.9.3 ANCHORAGE OF PIPE ON SLOPES ...................32 3.9.4 ANCHORAGE OF VALVES IN THE LINE .................33 3.9.5 CONSTRUCTION OF THRUST BACKING ...............33 3.10 INSTALLATION AT HYDRANTS .............................33 3.11 THRUST-RESTRAINT JOINTS .............................34 3.12 SERVICE CONNECTIONS ................................35 3.12.1 DIRECT TAPS, SADDLES, AND VALVES ...............35 4.0 PIPE EMBEDMENT .........................................35 4.1 BEDDING ..............................................36 4.2 BACKFILLING AND TAMPING ..............................36 4.2.1 HAUNCHING AND INITIAL BACKFILL ..................36 4.3 COMPLETING THE BACKFILL ..............................38 4.3.1 FINAL BACKFILL ..................................38 4.4 COMPACTION METHODS .................................39 4.4.1 TAMPING BARS 39 4.4.2 MECHANICAL TAMPERS ...........................40 4.4.3 FLOOD OR WATER TAMPING ........................40 4.4.4 WATER-JETTING ..................................41 4.4.5 SHEETING AND TRENCH BOXES .....................41 5.0 PIPE TESTING AND REPAIR ..................................41 5.1 PIPE DEFLECTION .......................................41 5.1.1 DEFLECTION TESTING .............................42 5.2 TESTING WATER PIPE ....................................42 5.2.1 FILLING THE LINE .................................43 5.2.2 RELIEVING AIR FROM THE LINE .....................45 5.3 PRESSURE-STRENGTH TESTS .............................45 5.4 MAKING LEAKAGE TESTS .................................46 5.5 MAKING REPAIRS TO DAMAGED PIPELINES ..................48 APPENDIX 1 .........................................49 THE PHYSICAL (OR CHEMICAL) PROPERTIES OF JM EAGLE" BLUE BRUTE"' PVC C.I.O.D. DISTRIBUTION PIPE (AWWA C900) BIG BLUE"' PVC C.I.O.D. TRANSMISSION PIPE (AWWA C905), ULTRA BLUE` PVCO C.I.O.D. DISTRIBUTION PIPE (AWWA C909), AND ULTRA BLUE"' PVCO I.P.S. DISTRIBUTION PIPE (ASTM F1483) PRESENTED IN THIS BOOKLET, REPRESENT TYPICAL AVERAGE VALUES OBTAINED IN ACCORDANCE WITH ACCEPTED TEST METHODS AND ARE SUBJECT TO NORMAL MANUFACTURING VARIATIONS. THEY ARE SUPPLIED AS A TECHNICAL SERVICE AND ARE SUBJECT TO CHANGE WITHOUT NOTICE. CHECK WITH JM EAGLE" PRODUCT ASSURANCE TO ENSURE CURRENT INFORMATION. HOW THIS GUIDE CAN HELP YOU This booklet was written especially for the installer and those who direct actual handling and installation of JM Eagle" PVC Blue Brute"', Big Blue"', and Ultra Blue" pipe. This guide should be used in conjunction with the following industry accepted installation and testing practices which are applicable. This document should not be considered a full guide or manual in lieu of: ASTM 02774-04 (or later) "Underground Installation of Thermoplastic Pressure Piping." ASTM F690-86 (2003) (or later) "Underground Installation of Thermoplastic Pressure Piping Irrigation Systems." ASTM F1668-96 (2002) (or later) "Construction of Buried Plastic Pipe." ASTM F645-04 (or later) "Selection, Design, and Installation of Thermoplastic Water-Pressure Piping Systems." ASTM 02321-05 (or later) Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity-Flow Applications." ASTM F1417-92 (2005) (or later) "Installation Acceptance of Plastic Gravity Sewer Lines Using Low-Pressure Air." AWWA C605 "Underground Installation of Polyvinyl Chloride (PVC) Pressure Pipe and Fittings for Water." 4 BLUE BRUTE`/BIG BLUE"'/ULTRA BLUE"' INSTALLATION GUIDE AWWA 0651 "Disinfecting Water Mains." AWWA M23 "PVC Pipe - Design and Installation." Uni-Bell® UNI-PUB-09 "Installation Guide for PVC Pressure Pipe." Uni-Bell® UNI-B-6 "Recommended Practice for Low-Pressure Air Testing of Installed Sewer Pipe." Uni-Bell® UNI-Pub-06 "Installation Guide for PVC Solid-Wall Sewer Pipe (4-15 Inch)." Uni-BelI® UNI-TR-1 "Deflection: The Pipe/Soil Mechanism." Uni-Bell® UNI-TR-6 "PVC Force Main Design." Uni-Bell® UNI-TR-7 "Thermoplastic Pressure Pipe Design and Selection." This guide is meant as an explanatory supplement to the materials above on how to install JM Eagle T1 PVC Blue BruteTM, Big Blue 1M, and Ultra Blue TM pipe under normal conditions so as to comply with Standard JM Eagle TM Laying Specifications. Any discrepancies between the above standards and the written information contained herein, should be brought to the attention of JM Eagle Product Assurance immediately for resolution by JM Eagle, prior to any actions by either contractor, engineer, or municipality. This guide is not intended to supply design information nor to assume the responsibility of the engineer (or other customer representative) in establishing procedures best suited to individual job conditions so as to attain satisfactory performance. Engineers, superintendents, contractors, foremen, and laying crews will find much to guide them in the following specifications. This booklet will also be of help in determining pipe needs when ordering. BLUE BRUTE-/BIG BLUE-/ULTRA BLUE'" INSTALLATION GUIDE 5 WARRANTY J-M Manufacturing Company Inc. (JM Eagle TM)warrants that its standard polyvinyl chloride (PVC), polyethylene (PE), conduit/plumbing/solvent weld and Acrylonitrile-Butadiene-Styrene (ABS) pipe products ("Products") are manufactured in accordance with applicable industry specifications referenced on the Product and are free from defects in workmanship and materials. Every claim under this warranty shall be void unless in writing and received by JM EagleTM within 30 days of the date the defect was discovered, and within one year of the date of shipment from the JM Eagle'" plant. Claims for Product appearance defects, such as sun- bleached pipe etc., however, must be made within 30 days of the date of the shipment from the JM Eagle TM plant. This warranty specifically excludes any Products allowed to become sun-bleached after shipment from the JM Eagle 1M plant. Proof of purchase with the date thereof must be presented to the satisfaction of JM Eagle'TM, with any claim made pursuant to this warranty. JM Eagle'TM must first be given an opportunity to inspect the alleged defective Products in order to determine if it meets applicable industry standards, if the handling and installation have been satisfactorily performed in accordance with JM Eagle TM recommended practices and if operating conditions are within standards. Written permission and/or a Return Goods Authorization (RGA) must be obtained along with instructions for return shipment to JM Eagle TIof any Products claimed to be defective. The limited and exclusive remedy for breach of this Limited Warranty shall be, at JM Eagle's sole discretion, the replacement of the same type, size and like quantity of non-defective Product, or credits, offsets or combination of thereof, for the wholesale purchase price of the defective unit. This Limited Warranty does not apply for any Product failures caused by user's flawed designs or specifications, unsatisfactory applications, improper installations, use in conjunction with incompatible materials, contact with aggressive chemical agents, freezing or overheating of liquids in the Product, and any other misuse causes not listed here. This Limited Warranty also excludes failure or damage caused by fire stopping materials, tread sealants, plasticized vinyl products or damage caused by the fault or negligence of anyone other than J M EagleTM, or any other act or event beyond the control of JM Eagle'TM. 6 BLUE BRUTE-/BIG BLUE-/ULTRA BLUE'TM INSTALLATION GUIDE JM Eagle's liability shall not, at any time, exceed the actual Wholesale purchase price of the Product. The warranties in this document are the only warranties applicable to the Product and there are no other warranties, expressed or implied. This Limited Warranty specifically excludes any liability for general damages, consequential or incidental damages, including without limitation, costs incurred from removal, reinstallation, or other expenses resulting from any defect. IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE SPECIFICALLY DISCLAIMED AND JM Eagle TMSHALL NOT BE LIABLE IN THIS RESPECT NOTWITHSTANDING JM Eagle's ACTUAL KNOWLEDGE THE PRODUCT'S INTENDED USE. JM Eagle's Products should be used in accordance with standards set forth by local plumbing and building laws, codes or regulations and the applicable standards. Failure to adhere to these standards shall void this Limited Warranty. Products sold by JM Eagle TMthat are manufactured by others are warranted only to the extent and limits of the warranty of the manufacturer. No statement, conduct or description by JM Eagle TIorits representative, in addition to or beyond this Limited Warranty, shall constitute a warranty. This Limited Warranty may only be modified in writing signed by an officer of JM Eagle1M. BLUE BRUTE'M/BIG BLUE-/ULTRA BLUE" INSTALLATION GUIDE 7 1.0 RECEIVING AND HANDLING PIPE SHIPMENTS Figure 1 1.1 INSPECTION Each pipe shipment shall be inspected with care upon arrival. Each pipe shipment is carefully loaded at the factory using methods acceptable to the carrier. The carrier is then responsible for delivering the pipe as received from JM Eagle'". All shipments include an adequate amount of lubricant for the pipe and a short form installation guide. IT IS THE RESPONSIBILTY OF THE RECEIVER TO MAKE CERTAIN THERE HAS BEEN NO LOSS OR DAMAGE (including smoke) UPON ARRIVAL. Check the materials, pipe, gaskets and fittings received against the bill of lading (tally sheet that accompanies every shipment) in accordance with the general guidelines below, reporting any error or damage to the transportation company representative and have proper notation made on the delivery receipt and signed by the driver. Present the claim in accordance with the carrier's instructions. Do not dispose of any damaged material. The carrier will advise you of the procedure to follow in order to procure samples and report the incident. MAKE OVERALL EXAMINATION OF THE LOAD. If the load is intact, ordinary inspection while unloading should be enough to make sure the pipe has arrived in good condition. IF LOAD HAS SHIFTED OR SHOWS ROUGH TREATMENT, THEN EACH PIECE MUST BE CAREFULLY INSPECTED FOR DAMAGE. 8 BLUE BRUTE`/BIG BLUE/ULTRA BLUE" INSTALLATION GUIDE CHECK THE TOTAL QUANTITIES OF EACH ITEM AGAINST THE TALLY SHEET (pipe, fittings, lubricant, etc.) ANY DAMAGED OR MISSING ITEMS MUST BE NOTED ON THE DELIVERY RECEIPT AND RETURNED TO THE TRANSPORTATION COMPANY. NOTIFY CARRIER IMMEDIATELY AND MAKE CLAIM IN ACCORDANCE WITH THEIR INSTRUCTIONS. DO NOT DISPOSE OF ANY DAMAGED MATERIAL. Carrier will notify you of the procedure to follow. SHORTAGES AND DAMAGED MATERIALS ARE NOT AUTOMATICALLY RESHIPPED. If replacement material is needed, reorder through your distributor and make them aware of the claim. 1.2 UNLOADING Figure 2 JM EagleTM Blue BruteTM, Big BlueTM and Ultra BlueTM Pressure Pipe is lightweight and may be unloaded by 1. Hand, either by passing over the side or off the truck ends. Sliding one length on another is standard practice in unloading PVC pipe, but lengths in the bottom layer should be lifted off of the rough surface of the truck body to avoid abrasion. 2. Conventional forklift, for large orders of pipe, which are bundled in pallets. Care shall be exercised to avoid impact or contact between the forks and the pipe. The means by which JM EagleTM PVC Blue Brute", Big Blue'" and Ultra Blue TMPressure Pipe is unloaded in the field is the decision and responsibility of the customer. Preferred unloading is in units using mechanical equipment such as forklifts, cranes, cherry pickers or front-end loaders with adequate forks, trained, competent BLUE BRUTE-/BIG BLUE-/ULTRA BLUE'" INSTALLATION GUIDE 9 operators, and equipment rated to safely handle the load. When unloading units, the following instructions should be carefully followed. Remove only one unit at a time. 1. Remove restraints from the top unit loads. These may be either tie down straps, ropes, or chains with protection. 2. If there are boards across the top and down the sides of the load, which are not part of pipe packaging, remove them. 3. Use a forklift (or front-end loader equipped with forks) to remove each top unit one at a time from the truck. Remove back units first. Do not run the forks too far under the unit as fork ends striking adjacent units may cause damage, or push other unit off opposite side of truck. Do not let forks rub the underside of pipe to avoid abrasion. 4. If a forklift is not available, a spreader bar on top and nylon strips capable of handling the load, spaced approximately eight (8) feet apart looped under the unit may be used. Cables may also be cushioned with a rubber hose sleeve or other material to prevent abrasion of the pipe. 5. During the removal and handling be sure that the units do not strike anything. Severe impact could damage the pipe (particularly during cold weather). 6. DO NOT: Handle units with chains or single cables. Attach cables to unit frames for lifting. 7. Units should be stored and placed on level ground. Units should be protected by dunnage in the same way they were protected while loaded on the truck. The dunnage must support the weight of all units so that pipe lengths do not carry the weight of the unit loaded above them. Units should not be stacked more than two (2) high. 8. To unload lower units, repeat the above unloading process (items 1 through 7). WARNING: PVC pipe, though lighter than other material, is still heavy and may be dangerous if not handled properly. Not adhering to the above instructions may result in serious injury to pipe, property, and/or persons. Do not stand or climb on units. Stand clear of pipe during unloading. 10 BLUE BRUTE"/BIG BLUE/ULTRA BLUE' INSTALLATION GUIDE NOTICE: Pipe at the bottom of a stack may become out-of-round due to the weight of material above it. At normal application temperatures this corrects itself soon after the load is removed due to the property of elastic memory. Under freezing conditions this recovery to full initial roundness may take several hours. 1.3 COLD WEATHER HANDLING As the temperature approaches and drops below freezing, the flexibility and impact resistance of PVC pipe is reduced. Extra care should be used in handling during cold weather to avoid any type of impact to the pipe to prevent damage. 1.4 STOCKPILES Store pipe on a flat surface so as to support the barrel evenly, with bell ends overhanging. If mechanical equipment is being used for handling, the unit bearing pieces provide an excellent base. If unloading by hand, secure two timbers for a base. Set them on a flat area spaced the same as a factory load. Nail chock blocks at each end. Build up the stockpile in the same manner, as it was stacked for shipment, transferring dunnage and chock blocks from load to stockpile. Store random lengths separately where they will be readily available. Individual lengths of pipe should be stacked in piles no higher than five (5) feet. It should be noted that when PVC pipe is stored outside and exposed to prolonged periods of sunlight, an obvious discoloration or UV degradation of pipe could occur. Based on the 24-month weathering study, the performance of PVC pipe was equally impressive. No significant changes in tensile strength at yield was observed. Reductions in impact strength were apparent after two years of exposure to weathering and ultra violet radiation. However, considering PVC pipe's high initial impact strength, the reductions were not significant enough to warrant concern. Pipe breakage due to impact loads encountered during normal handling and installation is not a problem with PVC pipe. This UV degradation does not continue after the pipe is removed from UV exposure. BLUE BRUTE'/BIG BLUE'-/ULTRA BLUE" INSTALLATION GUIDE 11 A method of protecting pipe during long exposures (several months) to sunlight is to cover it with canvas or other opaque material. Clear plastic sheets are not satisfactory. Allow for adequate air circulation between the cover and the pipe. This will prevent heat build-up and possible dimensional distortion. 1.5 GASKET CARE All JM Eagle1M PVC pipe is manufactured with factory installed gaskets. These gaskets cannot be easily removed or replaced outside of the factory. Keep them clean, away from oil, grease, excessive heat and electric motors, which produce ozone. It is advisable to keep gaskets protected from direct sunlight and temperature changes in order to avoid cracking in prolonged exposure for optimal performance. JM Eagle TMprovides a gasket that is approved for water service with its standard product. Special gasket types may be available for applications where oil resistance is required. Be sure the correct ring is ordered. See Section 3.4 for further information. 1.6 LOADING TRANSFER TRUCKS Use trucks with long bodies so that pipe lengths do not over hang more than two (2) feet. Make certain truck bed is smooth, without cross-strips, bolt heads, or other protrusions that could damage the pipe. Place the first layer carefully with the bell ends overhanging. Avoid sliding the pipe and abrading it. Subsequent layers can be slid into place. All bell ends should overhang the layer below. Short body trucks may be used if fitted with racks that properly support the pipe in the horizontal position. The rack shall support the pipe with supports spaced every three (3) feet or less along the pipe lengths. Pad the contact areas to avoid damage to the pipe. 12 BLUE BRUTE"/BIG BLUE/ULTRA BLUETM INSTALLATION GUIDE 1.7 DISTRIBUTING ALONG THE TRENCH In stringing out pipe, keep these points in mind: Line pipe as near to the trench as possible to avoid excessive handling. (Bell direction doesn't affect flow or hydraulic coefficients.) If the trench is open, it is advisable to string pipe on the side away from excavated earth wherever possible, so that the pipe can be moved easily to the edge of the trench for lowering into position. If the trench is not yet open, find out which side the excavated earth will be thrown; then string out on the opposite side (leave room for the excavator). Place the pipe so as to protect it from traffic and heavy equipment. Also, safeguard it from the effect of any blasting that may be done. 2.0 TRENCH CONSTRUCTION 2.1 WORKING AHEAD OF THE PIPE LAYING CREW Where soil and ground water conditions permit, long stretches of trench can be opened ahead of pipe laying, so as to take full advantage of the easy handling and speed of assembly of JM Eagle" PVC Blue Brute1M, Big Blue T"and Ultra Blue' pipe with elastomeric joints. However, for most jobs as a general rule, do not open the trench too far ahead of pipe laying. Avoiding these long stretches of opened trench may help with the economy of the project because: It may reduce or even eliminate pumping or sheeting. It minimizes the possibility of flooding the trench. It reduces caving caused by ground water. It helps avoid frozen trench bottom and backfill. It reduces hazards to traffic and workmen. On most jobs it will be desirable to keep excavating, pipe laying and backfilling close together. BLUE BRUTE'"/BIG BLUE-/ULTRA BLUE" INSTALLATION GUIDE 13 2.2 CURVES IN THE TRENCH 2.2.1 BLUE BRUTE TM AWWA 0900 (4 INCHES TO 12 INCHES) AND ULTRA BLUE TM AWWA 0909 (6 INCHES TO 16 INCHES) The trench may be curved to change direction or avoid obstructions within the limits of the curvature of the pipe as shown in Table 1: PIPE SIZE (inches) • MINIMUM RADIUS (feet) :. .:••••, •: OFFSET (in) 4 100 24.08 6 150 16.02 8 200 12.01 10 250 9.61 12 300 8.00 Table 1 * Offset based on 20 feet length of pipe forming a true arc. The line may be assembled above ground, in a straight line, and then curved when laid in the trench. All curvature results from the bending of the pipe lengths. The maximum angular deflection at the joint is 1 degree. The approximate force per 20-foot length in pounds to accomplish these curvatures is shown in Table 2 (based on DR): PIPE SIZE (inches) DR 25 DR 18 DR 14 4 16.36 21.62 26.32 6 47.21 60.85 74.25 8 102.77 135.79 165.29 10 185.35 245.54 299.27 12 309.09 407.09 498.65 Table 2 14 BLUE BRUTE`/BIG BLUE''/ULTRA BLUETM INSTALLATION GUIDE NOTICE: Mechanical means should not be employed to accomplish these radii. It is the intent that the workers should accomplish this manually in the trench. ON 4-INCH TO 12-INCH, THE CURVE CAN BE ACCOMPLISHED BY BENDING THE PIPE. TO AVOID OVER-STRESSING THE BELL AND TO PREVENT POSSIBLE BREAKAGE AND/OR LEAKS, THE MAXIMUM ANGULAR DEFLECTION IN THE JOINTS IS 1 DEGREE. To avoid deflecting the joints while achieving curvature, it is recommended that the joints be sufficiently braced or backfilled and compacted to keep them stationary. Abrupt changes in direction shall be accomplished with fittings. 2.2.2 BIG BLUE T`AWWA C905 (14 INCHES 1048 INCHES) AND ULTRA BLUE AWWA C909 (16 INCHES) Since the moment of inertia of Big Blue" Pressure Pipe is high, attempting to curve the pipe is extremely difficult. JM Eagle's recommendation for 14-inchthrough 48-inch-diameter Big Blue'TM and 16-inch Ultra' Blue'" is that the angular deflection at the joint is a maximum of 1.5 degrees. This will produce an offset in a 20-foot section of approximately 6.25 inches. Joint deflection is achieved after the joint is assembled in straight alignment and to the reference mark. The bell should be braced in order to allow the free end to move laterally under steady pressure using a pry bar or other suitable means. Care should be taken not to exceed the maximum deflection allowed or damage the pipe with the machinery used. The line may be assembled above ground, in a straight line then offset when laid in the trench, if necessary. Abrupt changes in direction shall be accomplished with fittings. NOTICE: AVOID OVER-STRESSING THE BELL (over-inserting the joints, or exceeding the maximum deflection/curvature allowed) IN ORDER TO PREVENT POSSIBLE BREAKAGE AND/OR LEAKS. BLUE BRUTE"/BIG BLUE"/ULTRA BLUE" INSTALLATION GUIDE 15 2.3 TRENCH WIDTHS Since JIM Eagle T11 PVC Blue BruteTM, Big Blue1M and Ultra Blue1M Pressure Pipe can be assembled above ground and lowered into position, trench widths can be kept to a minimum. The trench width at the ground surface may vary with and depend upon depth, type of soils and position of surface structures. The minimum clear width of the'trench, sheeted or unsheeted, measured at the spring-line of the pipe should be 1 foot greater than the outside diameter of the pipe. The maximum clear width of the trench at the top of the pipe should not exceed a width equal to the pipe outside diameter plus 2 feet. (See Figure 3.) This spacing will allow for proper compacting of the backfill to provide necessary sidewall s up Dort. It will also allow assembly work in the trench, if desired. If the above defined trench widths must be exceeded or if the pipe is installed in a compacted embankment, pipe embedment should be compacted to a point of at least 2.5 pipe diameters from the pipe on both sides of the pipe or to the trendh walls, whichever is less. Figure 3 NOTICE: PVC pipe is a flexible I pipe, so trench width and shape have little to no effect on loading experienced by the pipe, since the maximum load that may be carried by the pipe is that due to the column of soil directly above the pipe outside diameter. The trench width recommendations above help installers realize the economiesthat may result from installation of PVC pipe over other materials, while maintaining adequate control over backfilling, compaction and placement to limit long-term deflection. 16 BLUE BRUTE"/BIG BLUE/ULTRA BLUE` INSTALLATION GUIDE 2.4 TRENCH DEPTHS 11 Depth is governed by surface loads earth loads and frost penetration. A minimum of 12 inches depth of cover is recommended where frost penetration need not be considered. Where frost is a factor, pipe should be buried 6 inches below the greatest recorded frost penetration. If the line will be drained and not used in winter, frost need not be considered. Should unusual soil conditions and/or surface loads be anticipated and the engineer wants to calculate deflection when working with pressure pipes, "pipe stiffness" (f/Ay) can be found in Table 3 below: PIPE DR STIFFNESS (psi) PIPE DR STIFFNESS (psi) 64 7 25 129 51 14 21 224 41 28 18 364 35 46 17 437 32.5 57 14 815 26 115 - - Table 3 For more information on deflection, see Section 5.1. 2.5 PLANNING FOR THRUSTING Fittings used for changes in direction and all in-line valves will require thrust blocking or restraints, which must be formed against a solid wall. Do not machine dig at these fitting areas because the excavator will usually dig too far and damage the bearing surface of the trench wall. A small amount of hand digging just behind the fitting location will ensure a solid trench wall for thrust block construction later on. BLUE BRUTE"/BIG BLUE"/ULTRA BLUE" INSTALLATION GUIDE 17 2.6 PREPARATION OF TRENCH BOTTOM The trench bottom should be smooth and free from stones greater than 1.5 inches in diameter, large dirt clods, and any frozen material. Excavation at bells (bell holes) should be provided so that the pipe is uniformly supported along its length as seen in Figure 4. Figure 4 Generally, loose material left by the excavator on the trench bottom will be adequate for bedding the pipe barrel so that it is fully supported. Where the excavator cuts a very clean bottom, soft material can be shaved down from the sidewalls to provide needed bedding. If the trench bottom is rocky or hard, as in shale, place a 4-inch layer of selected backfill material to provide a cushion for the pipe. In rock excavation it is necessary that rock be removed and a bed of sand or selected backfill at least 4 inches deep be placed on the bottom of the trench to provide a cushion for the pipe. A pipeline of any material resting directly on rock, in the absence of a bedding cushion, is subject to breakage under the weight of the backfill load, surface load, or earth movements. When an unstable trench bottom is encountered and, in the opinion of the engineer, it cannot support the pipe, an additional depth should be excavated and refilled to the pipe grade with material approved by the engineer. Trenches can be dangerous, and the contractor has the responsibility of ensuring that all safety regulations and design requirements have been observed for the protection of the workers and the public. 2.7 CASINGS 2.7.1 PLACEMENT OF CASINGS The placement of casings requires special equipment and skills. It is a specialized field of construction, to which some construction firms devote their entire efforts. 18 BLUE BRUTE`/BIG BLUE/ULTRA BLUE" INSTALLATION GUIDE In the smaller diameters, the steel casing is usually placed progressively, following the boring equipment as it tunnels through the obstruction. The recommended practice is to use plain steel pipe (not corrugated) for the casing to facilitate movement of the PVC pipe through the casing with a minimum of resistance. For larger diameters, most of the casing construction is done by jacking the pipe from excavated pits. Where long casings are involved, numerous pits for jacking operations are required along the route. Regardless of the diameter, accuracy in alignment and grade of the casing pipe is very important in maintaining the established inverts. 2.7.2 PULLING THE PIPE When PVC pipe is to be installed in casings under highways or railroad tracks, skids with rounded ends must be used to prevent the pipe and bells from snagging on the inside of the casing, and to keep the installed line from resting on the bells of the pipe. Skids shall be thick enough to allow clearance between the bells and the casing bottom. Normally two to four skids are only placed on the pipe spaced at 90 degrees as shown in Figure 5. For pipe larger than 18 inches, six skids should be placed at 60 degrees apart. Cable Strapping Wn -cl rrccs nir \ A Skids Figure 5 A cable is passed through the casing and the first pipe length is fastened to a suitable wood crosspiece at the end of the pipe. The cable is then pulled steadily by a winch, tractor or other method until about 2 feet of pipe is left projecting out of the casing for assembly of the next length. (If cable is pulled at an angle, make sure that the leading pipe end is protected from damage.) The cable is then passed through the next pipe and the two pipes are assembled. This operation is continued until the pipe is completely through the casing. BLUE BRUTE"/BIG BLUE'/ULTRA BLUE" INSTALLATION GUIDE 19 NOTICE: In order to prevent over-insertion of the pipe joint while installing it through casings, some method of restricting the movement between the assembled bell and spigot must be provided. Four such assemblies should be made at 90-degree spacing around the pipe bells. All "B" Skids must be tightly strapped to the pipe by metal strapping or similar material. Also, note that all skids should be notched and leveled so that they form a smooth, flat bottom. This is necessary so that no portion of the pipe is carrying the total load. An illustration of one proposed method is shown in Figure 6. Metal Strap ZE Stop Mark 3" Details I 1 '1 1½" 3" "B" Skid 24" to 30" T "A" Skid 11/2" x 4" "F" dimention + 6" Figure 6 The inserted PVC pipelines should be circumferentially braced in the casing to prevent movement in any direction. In force sewer mains, movement can be caused by the thrust action generated by a slightly deflected joint. For gravity flow lines, movement of the inserted pipe may be caused by floatation from flooding of the annular spaces at each end of the casing. It is recommended that these spaces be sealed as described in Section 2.7.3. 20 BLUE BRUTE"/BIG BLUE"/ULTRA BLUE' INSTALLATION GUIDE In some cases, small pipe in larger casings may require skids or positioning braces placed around the entire circumference of the pipe to keep the pipe in proper alignment in the casing. When pipe is pulled into a casing with a cable, the pipe may rotate, causing the skids and positioning braces to rotate from their entry position. Consequently, if a sufficient number, size and circumferential spacing of skids and braces are not employed, the bells cannot be kept from contacting the casing surfaces. Lubricating the casing or skids will make sliding easier. Depositing drilling mud or flax soap at the end of the casing can lubricate the casing. Then attach rags to the cable and pull them through so that they act as swabs or spreaders. A rope attached to the cable will make it easy to retrieve. Petroleum products, such as oil and grease, should not be used as lubricants since prolonged exposure to these products is detrimental to the rubber gaskets used to seal the joints. PVC pipe may also be pushed through the casing, using equipment, which will exert a constant and uniform force against the pipe end. To accomplish this, the pushing equipment must be firmly anchored and the joints sufficiently braced. 2.7.3 CLOSURE OF CASING AFTER PIPE INSTALLATION Under no circumstances should the ends of the casing be closed or any material installed inside the casing until the completion of the pressure test and approved by the engineer. After testing, the ends of the casing should be sealed off. A generally accepted practice is to sack the end of the casing, leaving an opening on the bottom. Sacking is to be placed between the PVC pipe and the casing except that the areas at the bottom between the skids are to be left open. This will keep backfill out of the casing, while allowing for drainage. The casing should not be backfilled with sand unless specified by the engineer. When sand is used, drainage is obstructed and access to the interior of the casing is made more difficult. Also, if the sand is packed tightly, the load on the casing may be transferred to the PVC pipe, thus nullifying the purpose of the casing. Where backfilling of the annular space under and around the encased pipe is required, three-fourths of the distance to the top of the BLUE BRUTE'/BIG BLUE'"/ULTRA BLUER' INSTALLATION GUIDE 21 casing should be filled with sand or other approved material. Again, the areas between the skids (under the pipe) should be left open for drainage. Using a hose line, sand can be forced into the casing with water under pressure. Care must be taken to avoid forcing too much water into the casing because of the possibility of floating the pipe. Floatation could result in uneven support for the encased pipeline if the skid system fails to prevent movement in all directions. NOTICE: Under no circumstances should any blocks or spacers be wedged between the pipe and the top of the casing. Pressure grouting when not strictly controlled can collapse PVC pipe. Pressure grouting is sometimes specified for filling in the annular space between the pipeline and the casing. If pressure grouting is to be utilized, it will be necessary to arrange the skids and position braces on the pipe so as to accommodate a 2-inch grouting hose. The recommended pressure grouting method is as follows: Arrange the skids and position braces on the pipe as shown in Figure 6. They will accommodate the grouting hose. Secure the grouting hose to the leading end of the first pipe section before insertion begins. Either push or pull the pipe into the casing, channeling the hose in place on the leading end of each succeeding section of pipe. Cap or plug each end of the bore, leaving an air hole at the top of the low end and a hole at the top of the high end for the grouting hose to pass through. Use a grout mixture in a ratio of four (4) parts cement to one (1) part sand, with sufficient water to yield a consistency of thick soup. Start pumping very slowly. A sensitive pressure gauge should be mounted on the discharge outlet of the grouting machine. A pressure will develop equal to pressure needed to deliver the grout through the hose. After this pressure is established, any increase in pressure by 2 or 3 psi will indicate a need to pull the grouting hose slightly until the pressure returns to the established 22 BLUE BRUTE`/BIG BLUE'/ULTRA BLUE" INSTALLATION GUIDE average delivery pressure. It is essential that the pressure generated does not exceed 2 or 3 psi over the initial required delivery pressure. Continue this procedure until the bore is 3/4 of the way full. NOTICE: Wooden skids in backfill should have a long life. The life of the skids will be further extended if they are treated before backfilling. If there is to be no backfill, it is important that the skids be treated with a wood preservative. Functionally, it is not necessary to backfill around the pipe inside the casing with sand or any other material. 3.0 PIPELINE CONSTRUCTION 3.1 INSPECTION Pipe and accessories should be inspected for defects and cleanliness prior to lowering into the trench. Any defective, damaged or unsound material should be repaired or replaced and foreign matter or dirt should be removed from the interior of the pipe and accessories before lowering into the trench. 3.2 LOWERING PIPE AND ACCESSORIES INTO TRENCH All pipe, fittings, valves and accessories should be carefully lowered into the trench using suitable equipment in such a manner as to prevent damage to pipe and accessories. PIPE AND ACCESSORIES SHOULD NEVER BE DROPPED OR DUMPED INTO THE TRENCH. CAUTION: Heavy impact may cause a slight longitudinal indentation in the outside of the pipe and a crack on the inside. This will result in a split as soon as the pipe is placed under pressure. Any pipe that has been impacted should be examined closely for this type of damage. )E 23 3.3 ASSEMBLY OF JM EAGLE T11 PVC PIPE The joint assembly is a push-on assembly in which the lubricated spigot end is inserted under the rubber gasket and into the bell as described in this installation guide. The joint assembly pro'ides for the completion of tight, dependable joints in minimum time when the following procedure is adhered to. 3.4 ASSEMBLY INSTRUCTIONS JM Eagle TMsupplies a standard gasket for water service with its pressure products and an oil resistant gasket under special request. The correct gasket for water service is not marked with any identifiers. The oil resistant gasket for special services has a blue band on the visible gasket face. Be sure you have the correct gasket for the installation. If you require oil resistant gaskets and those provided are for water service, contact JM Eagle' immediately. Do not use the water service gaskets or try to replace them. Note that either ring type may be used for conveying potable water. Field removal and replacement of gaskets is not recommended. Make certain that the gasket and bell is clean, with no dirt or foreign material that could interfere with proper seating of the gasket or assembly. If necessary, wipe the gasket and bell with a clean, dry cloth, as seen in Figure 7. Lubricating the gasket is not recommended. Make sure pipe end is clean. Wipe with a clean dry cloth around the entire circumference from the end to 1 inch beyond the reference mark. Lubricate the spigot end of the pipe, using only the JM Eagle TM-approved pipe lubricant (NSF approved) supplied. Be sure to cover the entire spigot end circumference, with particular attention paid to the beveled end of the spigot. (See Figure 8.) The coating should be the equivalent of a brush coat of enamel paint. Lubricant can be applied to the pipe by hand, cloth, pad, sponge or glove. Lubrication of the gasket and/or ring groove may result in displacement during assembly. 24 BLUE BRUTE1M/BIG BLUE/ULTRA BLUE" INSTALLATION GUIDE Figure 7 CAUTION: After spigot end is lubricated, do not allow it to contact the bedding material. Small pieces of stone or soil may adhere to the lubricant and may become lodged between the spigot and the gasket upon assembly, resulting in a possible leak. Figure 8 NOTICE: The JM EagleTM lubricant supplied with each shipment has been tested and approved for potable water service. Do not use non-approved lubricant, which may harbor bacteria or damage the gaskets or drinking water. 4. Insert the beveled spigot end into the bell so that it is in contact with the gasket. Hold the pipe lengths being joined close to the ground (as shown below) and keep the lengths in proper alignment. Brace the bell, as shown in Figure 9, while the spigot end is inserted under the gasket, so that previously completed joints in the line will not be closed up or over-assembled. Push the spigot end in until the reference mark on the spigot end is flush with the end of the bell, as seen in Figure 10. Stabbing is not recommended and should be avoided to prevent damage to the gasket and joint. 1 BLUE BRUTE/BIG BLUE-/ULTRA BLUE" INSTALLATION GUIDE 25 Figure 9 CAUTION: If joint is over-assembled, causing the spigot to jam into the neck of the bell, flexibility of the joint is lost. Uneven settlement of the trench or additional loading may cause this type of joint assembly to leak or crack. Do not assemble beyond the reference mark. Figure 10 If undue resistance to insertion of the beveled end is encountered or the reference mark does not reach the flush position, disassemble the joint and check the position of the gasket. If it is twisted or pushed out of its seat, do not attempt to realign gasket, replace with another piece of pipe. Be sure both lengths are in proper alignment. NOTICE: Should a spigot or bell end become deformed under load at higher temperatures, it will be necessary to exercise more care in assembling the joint in order to prevent fish-mouthing of the gasket. 5. No deflection at joint is allowed on 12-inch and smaller pipe. Pipe curvature should be accomplished by bending the pipe rather than deflecting the joints as noted in Section 2.2. 26 BLUE BRUTE`/BIG BLUE-/ULTRA BLUE INSTALLATION GUIDE NOTICE: If a pry bar, or backhoe is used for any assembly, a wood plank should be placed between the pipe and the machine to prevent damage. In addition, the force applied must be steady and constant. Do not ram or hit the pipe. For all pipe, a come-a-long jack is recommended over a backhoe. The method of attachment to the pipe must not abrade or damage the pipe in any way. Steps must be taken during installation using these methods to maintain correct alignment of the pipe. As well, a helper should be present in all cases to assist the operator in knowing when the reference mark is reached properly. 3.5 CUTTING A square cut is essential to ensure proper assembly and/or beveling. PVC pipe can easily be cut with a fine-toothed hacksaw, handsaw or a power type saw with a steel blade or abrasive disc. (See Figure 11.) (Do not use standard pipe cutters. The cutting wheel may crush or damage the pipe.) It is recommended that the pipe be marked around its entire circumference prior to cutting to ensure a square cut. Do not burn the pipe while cutting. Figure 11 NOTICE: JM EagleTM recommends using proper personal protective eqipment, such as gloves and safety glasses, when cutting PVC pipe. J BLUE BRUTE"/BIG BLUE-/ULTRA BLUE' INSTALLATION GUIDE 27 3.6 BEVELING Use a factory-finished beveled end as a guide to determine the angle and length of taper. The end may be beveled using a plastic pipe-beveling tool as shown, which will cut the correct taper automatically or such tools as the Stanley "Surform" No. 399, a coarse file or rasp. A portable sander or abrasive disc may also be used to bevel the pipe end. Remove all burrs and raised edges prior to assembly to avoid cutting the gasket. 3.7 LOCATING REFERENCE MARK With a pencil, crayon or permanent marker, locate the reference mark at the proper distance from the beveled end. The reference mark may also be located accurately by using a factory-marked end of the same pipe as a guide. 3.8 ASSEMBLY AT FITTINGS AND ADAPTORS JM Eagle TIPVC Blue Brute TM, Big BluerTM and Ultra BlueTM pipe is manufactured with a Cast Iron Outside Diameter. This means that this pipe can be directly connected to C.I.O.D. products and fittings such as ductile iron accessories. No extra support need be provided for these fittings and adaptors, but any heavy metal fittings or valves must be individually supported to avoid differential settlement between fittings and pipe. Note that fittings and valves in-line will require thrust blocking as specified in Section 3.9. NOTICE: Solvent Weld PVC fittings can not be used with Ultra Blue' pipe. NOTICE: Use only M.J. fittings approved for use with AWWA C909 pipe. Follow M.J. fittings manufacturer's assembly recommendations. NOTICE: The use of certain mechanical joint butterfly valves with DR 14 PVC pipe may require special adapters due to interference of the pipe wall and valve flap. Do not cut or trim the pipe wall to avoid decreasing the pressure rating. Fittings and adaptors are usually installed at predetermined locations and therefore, a tie-in length of less than 20 feet will usually be required. 28 BLUE BRUTE`/BIG BLUE'M/ULTRA BLUE" INSTALLATION GUIDE Be sure the correct gasket is used with the iron bell or fitting. Do not use the PVC gasket. Bevel on the spigot should approximate the cast iron bevel, which is shorter and steeper. The reason for this is that the depth of the bell or fitting is shorter than the PVC bell. The reduced length of taper will allow a greater flat sealing surface and minimize the possibility of the gasket seating on the bevel, which may cause leakage. When connecting to a mechanical joint or flanged fitting, a beveled spigot is not recommended or required. Cut off beveled end of pipe prior to insertion into JM EagleTM style fitting. 3.9 THRUST BLOCKING AND ANCHORAGE AT FITTINGS Thrust backing (Figure 12) is needed wherever the pipeline: Changes direction, as at tees, bends or crosses. Changes in size, as at reducers. Stops, as at dead ends. Valves at which thrust develops when closed. Figure 12 3.9.1 DETERMINING SIZE AND TYPE OF THRUST BLOCKING Size and type of blocking depends on pressure, pipe size, kind of soil and type of fitting. Common thrust block configurations are shown in Figure 13. At vertical bends, anchor pipelines to resist outward or horizontal thrusts as shown in Figure 14. If thrusts due to high pressure are expected, anchor the valves as shown in Figure 15. In all cases, thrust blocking and anchorages should be designed by a competent engineer to ensure adequate safety and BLUE BRUTE'/BIG BLUE-/ULTRA BLUE'" INSTALLATION GUIDE 29 support based on the actual field conditions encountered. Failure to design thrust blocking and anchorage adequately may result in damage to the pipe, property, and/or people. . :.•••••... _. £- -•\ Figure 13 If the engineer has not specified the size of a thrust block, take the following steps to determine the bearing area required for a thrust block. EXAMPLE: A 90-degree bend for an 8-inch 200 psi line, which will be tested at 200 psi. Soil is sand. Refer to Table 4 and note that the thrust developed for each 100 psi water pressure at an 8-inch 90-degree bend is 9,100 pounds. Yielding a total thrust developed of 18,200 lbs. In Table 5, find that the bearing power of sand is 2,000 pounds per square foot (psf). Dividing the total force of 18,200 pounds by 2,000 psf, we have a total area of thrust backing required of 9.1 square feet or an area of 3 feet by 3 feet. NOTICE: Allowance in total bearing area should be made for possible water hammer in the line. 30 BLUE BRUTE`/BIG BLUE'/ULTRA BLUER' INSTALLATION GUIDE THRUST (psf) AT FITTINGS PRODUCED BY 100 psi OF WATER PRESSURE IN JM EAGLE" PVC PRESSURE PIPE PIPE SIZE (inches) FITTING 90 BEND 45 ELBOW TEE AND PLUGS 4 2,560 1,390 1,810 .6 5,290 2,860 3,740 8 9,100 4,920 6,430 10 13,680 7,410 9,860 12 19,350 10,470 13,690 14 25,990 14,100 18,380 16 33,630 18,280 23,780 18 42,230 22,970 29,860 20 51,820 28,180 36,640 24 73,930 40,200 52,280 30 113,946 61,927 80,425 36 163,228 88,711 115,209 42 220,353 119,757 155,528 48 278,188 151,189 196,350 Table 4 ALLOWABLE :11 BEARING O SOILS SOIL BEARING (psf) Muck, peat, etc. 0 Soft Clay 1,000 Sand 2,000 Sand and Gravel 3,000 Sand and Gravel cemented with Clay 4,000 Hard Shale. 10,000 Table 5 * JM Eagle' assumes no responsibility for the bearing load data, which was compiled from various sources. The engineer is responsible for determining safe bearing loads and when doubt exists, soil-bearing tests should be '-I BLUE BRUTE"'/BIG BLUE"/ULTRA BLUE'" INSTALLATION GUIDE 31 specified. The bearing loads given are for horizontal thrusts when depth of cover is 2 feet. In soft, unstable soils such as muck or peat, thrusts are resisted by running corrosion-resistant tie rods to solid foundations or by removing the soft material and replacing it with a ballast of sufficient size and weight to resist the thrusts developed. Pre-cast thrust blocks should not be placed directly against PVC pipe to avoid point loading and provide adequate force distribution. 3.9.2 UPWARD THRUSTS AT FITTINGS Where a fitting is used to make a vertical bend, anchor the fitting to a thrust block braced against undisturbed soil. The thrust block should have enough resistance to withstand upward thrusts at the fitting. See Figure 14. Figure 14 3.9.3 ANCHORAGE OF PIPE ON SLOPES Anchors on slopes are needed only when there is the possibility of backfill slipping downhill and carrying the pipe with it. Usually, well-drained soil, carefully tamped in 4-inch layers up to the top of the trench, will not slide and pipe anchors will not be required. Where soil slippage is a possibility, anchors keyed in undisturbed soil can be fastened to every other length of pipe. 32 BLUE BRUTE`/BIG BLUE/ULTRA BLUE INSTALLATION GUIDE 3.9.4 ANCHORAGE OF VALVES IN THE LINE Under pressure conditions, valves must be anchored, as shown in Figure 15, against the thrust created when the valve is closed. The area of undisturbed soil, which braces the thrust block, must be large enough to withstand the thrust in whatever direction it is exerted. Figure 15 3.9.5 CONSTRUCTION OF THRUST BACKING Concrete thrust blocks are constructed by pouring concrete between the fitting and the undisturbed bearing wall of the trench. A dry mixture is prepared so that the concrete may be easily shaped into the desired form, a wedge with the wide end against the solid wall. Note the shapes and positions of the thrust blocks in the drawings. Cinder blocks, wood, dry sand-cement mix or other materials may be used for pipe sizes less than 6 inches provided that (a) there is sufficient bearing area between backing and fitting, and (b) the backing has sufficient strength to withstand the thrust load. If wood is used, it must be treated to prevent deterioration. As an alternative, mechanical thrust restrainers may be used to resist the thrust developed. 3.10 INSTALLATION AT HYDRANTS Each hydrant run-out is normally equipped with a valve. The valve may be located at the main, at the hydrant or in between. Whatever the location, each fitting (branch-tee, gate valve and hydrant) should be separately supported by concrete. Be sure to firmly brace the hydrant while pipe connections are made and until the final foundation has been poured and has set. Do not make the pipe support the hydrant. BLUE BRUTE''/BIG BLUE/ULTRA BLUE" INSTALLATION GUIDE 33 A concrete foundation poured around the base of the hydrant after it has been set in position, as seen in Figure 16, will serve as: - A thrust block. - A hold-down or anchorage against frost heave. - A foundation that eliminates washouts from the wastewater discharged through the hydrant drain. Pour the base after hydrant has been set Anchor rod Hydrant \4 drain Elevation Plan Figure 16 When the fittings are used in a hydrant run-out, seen in Figure 18, a single length can be used to connect two fittings. Figure 17 3.11 THRUST-RESTRAINT JOINTS Various types of thrust-restraint joints are currently promoted for use with PVC pipe. These include couplings, which require grooving the pipe and various fittings with setscrews that bear on the pipe wall. None of these devices can be uniformly recommended by JM Eagle TMfor use with our products. Contact JM Eagle TMProduct Assurance for specific application information with regard to specific joint restrainers. 34 BLUE BRUTETM/BIG BLUE"/ULTRA BLUETM INSTALLATION GUIDE Fittings Ultra Blue1M has ductile iron (Dl) outside diameters (00), making standard PVC gasketed fittings compatible. (Note: Solvent Weld PVC fittings cannot be used.) Ductile iron or cast iron mechanical joint fittings and ductile iron push-on-type fittings can be installed directly onto Ultra Blue TM, using the standard M.J. gasket made for cast iron or ductile iron pipe. When using M.J. fittings, 55 feet/pounds of torque is recommended. Joint Restraint Devices Joint restrain devices that are commonly used with standard PVC can be used with Ultra BlueTM. 3.12 SERVICE CONNECTIONS Service connections may be made to JM Eagle'" PVC pressure pipe by means of direct tapping, saddles or a sleeve and valve in the line at the service location. Due to the in-depth knowledge required to make proper taps safely, please refer to Uni-Bell® Publication UNI-PUB-08-07, "Tapping Guide for PVC Pressure Pipe." 3.12.1 DIRECT TAPS, SADDLES, AND VALVES With these connections, a JM Eagle1M PVC pressure pipeline can be tapped before or after the line goes into service. Check with saddle and valve manufacturers for recommended pressure rating of the tools used. WARNING: Use of improper tapping procedures or tools may result in serious damage to pipe, property and/or people. Do not tap prior to obtaining the complete tapping guide. 4.0 PIPE EMBEDMENT Figure 18 illustrates a typical trench with all major regions identified, as they will be addressed in the following sections. BLUE BRUTE-/BIG BLUE-/ULTRA BLUE'" INSTALLATION GUIDE 35 Pipe Springline zone of pipe Initial backfill Embedment Material Haunching Bedding max. 6 in Foundation (may not be required) Figure 18 4.1 BEDDING Bedding is required primarily to bring the trench bottom up to grade. Bedding materials should be placed to provide uniform longitudinal support under the pipe to prevent low spots. Blocking should not be used to bring the pipe to grade. Bell holes at every joint will allow for the joint to be assembled properly and maintain adequate support. Under normal circumstances a bedding of 4 to 6 inches compacted is of sufficient thickness for the bedding. If the native trench soil is comprised of fine-grain soils and migration of those soils into the bedding material is anticipated, either wide-trench construction, a well- graded bedding material without voids, or a fabric barrier should be used to avoid compromising the trench backfill materials. 4.2 BACKFILLING AND TAMPING Backfilling should follow pipe assembly as closely as possible. This protects the pipe from falling rocks, eliminates possibility of lifting the pipe from grade due to flooding of an open trench, avoids shifting pipe out of line by cave-ins, and in cold weather lessens the possibility of backfill material becoming frozen. 4.2.1 HAUNCHING AND INITIAL BACKFILL There are two basic purposes of the haunching and initial backfilling of a flexible conduit such as PVC pipe: 36 BLUE BRUTE-/BIG BLUE'/ULTRA BLUE' INSTALLATION GUIDE To provide the soil side support, which is necessary to enable the pipe and the soil to work together to meet the designed load requirements within the allowable deflection limits. To provide protection for the pipe from impact damage due to large rocks, etc., contained in the final backfill. The essentials of satisfactory haunching and initial backfilling can be summarized as follows: Provide approved materials, properly compacted continuously above the bedding and around the pipe to the spring-line, as well as between the pipe and undisturbed trench walls. After the bedding material has been placed according to Section 4.1, place the haunching and initial backfill by hand to a 1-foot minimum depth of cover above the pipe to give pipe support and cushion. In doing so, proper control should be exercised to avoid vertical and horizontal displacement of the pipe from proper alignment. This backfill should be a selected material, free from rocks greater than 1.5 inches in diameter, dirt clods or frozen material. This material is solely responsible for providing effective support of the pipe in the haunching area and limiting deflection. This is accomplished by tamping the embedment materials under the haunches and around the pipe to the spring-line of the pipe. Side support is accomplished by tamping the soil firmly under the haunches of the pipe out to the trench walls. Tamping should be done in layers no greater than 6 inches. If automatic tampers are used, care should be exercised to avoid damaging the pipe. For more information on tamping, see Section 4.4.1. I Ij.! lull lu1 ll ,Il1 1 1 .lIII.1 .1lII.I .IlII,I I III.I .1III.I I iii Right—Backfill correctly placed by hand filling all voids. 0111 I I•I. Wrong—Backfill not placed evenly. Figure 19 BLUE BRUTE'/BIG BLUE-/ULTRA BLUE' INSTALLATION GUIDE 37 The immediate placement of initial backfill will provide adequate weight of soil on the pipe so that expansion and contraction will be evenly distributed over each pipe length. This portion of the backfill begins at the spring-line of the pipe and extends to some predetermined distance above the pipe. Since little to no side support is derived from the soils placed in this area, native soils maybe used without tremendous compaction efforts, unless in the influence zone of other structures. It should be noted that at shallow depths of cover (less than 3 feet) flexible conduits may deflect and rebound under dynamic loading if the trench width is not highly compacted, resulting in damage to road surfaces. For pipes buried under flexible road surfaces at depths less than 3 feet, it is recommended that a minimum of 90 percent Proctor density be achieved from the bottom of the trench up to the road surface using Class I or Class II materials as described in Appendix 1. Minimum cover is recommended to be 1 foot from the top of rigid road surfaces or the bottom of flexible road surfaces. NOTICE: For water pipe installations the top area of the bells can be left exposed for visual inspection during the test if required. Balance of backfill need not be as carefully selected as the initial material, unless specified by the engineer. Care should be taken, however, to avoid including large stones that could damage the pipe by dropping on it or by being forced down on to the pipe under the weight of the final backfill. 4.3.1 FINAL BACKFILL The final backfill should be placed and spread in uniform layers in such a manner as to completely fill the trench with a uniformly dense backfill load on the pipe and avoid unfilled spaces in the backfill. Rolling equipment should not be used until a minimum of 18 inches of backfill material has been placed over the top of the pipe. If a hydro hammer is to be used to compact the backfill, a minimum of 3 feet of cover is required. Unless otherwise specified, trenches under pavements, sidewalks, or roads shall be backfilled and compacted to 90 percent density, as determined by the American Association of Highway and Transportation Officials Method 38 BLUE BRUTE`/BIG BLUE/ULTRA BLUE" INSTALLATION GUIDE T99 for State Compaction and Density of Soils. Unless specified, other trenches may be backfilled without controlled compaction in the final backfill. Additional backfill material should be supplied, if needed, to completely backfill the trenches or to fill depressions caused by subsequent settlement. For description of backfill materials and their recommended usage, please refer to Appendix 1. 4.4 COMPACTION METHODS The first step in providing effective support for the pipe in the haunching area is to tamp the embedment materials under the haunches and around the pipe to the spring-line of the pipe. Tamping should be done with hand tamping bars, mechanical tampers, or by using water to consolidate the embedment materials. With hand tamping, satisfactory results can be accomplished in damp, loamy soils and sands. For more cohesive soils, the necessary compaction may require the use of mechanical tampers. Water tamping should be limited to trenches excavated in soils in which water drains through quickly and, in so doing, compacts the embedment material. 4.4.1 TAMPING BARS Two types of tamping bars should be available for a good tamping job. The first should be a bar with a narrow head. (See A or B of Figure 20.) These are used to tamp under the pipe. The second tamping bar should have a flat head. It is used to compact the soil along the sides of the pipe to the trench walls. (See Figure 20 C.) BLUE BRUTE'/BIG BLUE /ULTRA BLUE' INSTALLATION GUIDE 39 3/41 - 1 or 11/4" pipe 300 bend weld to flat bar 6" x 4" x 1 tee and two A B 4" nipples 10, Figure 20 Do not attempt to use the flat tamper (C) in place of A or B 4.4.2 MECHANICAL TAMPERS Care should be taken to avoid contact between the pipe and compaction equipment. Compaction of the embedment material should generally be done in such a way that the compaction equipment is not used directly above the pipe until sufficient backfill has been placed to ensure that the use of compaction equipment will not damage the pipe or cause deflection of the pipe. When hydro-hammers are used to achieve compaction, they should not be used within 3 feet of the top of the pipe and then, only if the embedment material density has been previously compacted to a minimum 85 percent Proctor density. 4.4.3 FLOOD OR WATER TAMPING Flooding or water tamping should be used only in trenches that are excavated in soils from which water drains quickly and, at the same time, compacts the haunching material. If flooding is used, the approved embedment material is first hand placed, making certain all voids under, around and along both sides of the pipe and 40 BLUE BRUTE"/BIG BLUE/ULTRA BLUE" INSTALLATION GUIDE L couplings are filled. Initial embedment material should be placed to a height sufficient to prevent floating of the pipe. 4.4.4 WATER-JETTING The introduction of water under pressure to the embedment material is not to be used to compact the embedment material of PVC pipe, or any other flexible conduit. 4.4.5 SHEETING AND TRENCH BOXES When sheeting is used, it should be left in place unless it is designed to prevent disturbing the soil adjacent to the pipe when pulled and removed. If heavy wooden sheeting has to be pulled, well-graded granular material should be placed on each side of the pipe for a distance of at least two pipe diameters. The granular material should be compacted to at least 90 percent standard Proctor density. Whenever possible, sheeting and bracing should be installed so that the bottom of the sheeting extends no lower than the spring-line of the pipe. When installed in this manner, pulling the sheeting will not disturb the embedment material providing sidewall support for the pipe. If a trench box is used, it should be designed so that the back end of the sides do not extend below the pipe spring-line. This will allow filling and compaction of the annular space as the trench box is moved forward. 5.0 PIPE TESTING AND REPAIR 5.1 PIPE DEFLECTION Under ordinary circumstances the deflection of PVC pressure pipe is of no concern because the internal pressure of the pipe is much greater than the external load placed on the pipe, thus no deflection occurs. However, in some cases, these pipes are used for force mains or gravity flow applications. Towns and municipalities normally set the long-term deflection limits of PVC at 7.5 BLUE BRUTE"/BIG BLUE'/ULTRA BLUER' INSTALLATION GUIDE 41 percent by ASTM D3034 (Appendix), to provide a very conservative factor of safety against structural failure. However, it should be noted that PVC sewer pipe will have a minimum safety factor of 4 in structural failure at this limit. To ascertain how a certain PVC product will deflect under various loading conditions, backfill types, and depths one may contact JM Eagle'" for design charts specific to a situation. 5.1.1 DEFLECTION TESTING It is the position of JM Eagle1" that deflection testing of PVC pipe is unnecessary when pipe is installed in accordance with the acceptable practices stated in this guide. Most towns and municipalities limit initial deflection to 5 percent, when in actuality ASTM D3034 recommends PVC pipe deflection at 7.5 percent of base inside diameter. Thus, exceeding these limits does not necessarily indicate any structural damage, failure or reduction in life and only add to the cost of the project. Proof of this position is that more than 750,000,000 feet of PVC sewer pipe are performing satisfactorily in the field today. On the other hand, where improper installation practices are known or suspected, questionable bedding materials are employed, and/or installation conditions are severe, deflection testing of these sections of the installation should be considered advisable by the engineer. In the event that deflection measurement is a requirement, please consult JM Eagle" Publication JME- 05B, "Gravity Sewer Installation Guide." 5.2 TESTING WATER PIPE It is good practice to pressure test portions of a line as it is installed—before the entire line is completed. Before testing, all parts of the line should be backfilled and braced sufficiently to prevent movement under pressure. In setting up a section of line for test, a provision for air relief valves should be made. There are three parts of the line to consider when testing: 1. The run of pipe, which must be backfilled sufficiently to prevent movement under test pressure. 42 BLUE BRUTE'"/BIG BLUE"/ULTRA BLUE'" INSTALLATION GUIDE Thrust blocks at fittings, which should be permanent and constructed to withstand test pressure. If concrete thrust blocks are used, enough time to permit the cement to set must elapse before testing. Test ends, which should be capped and braced to withstand the appreciable thrusts that are developed under test pressure, as seen in Figure 21. Refer to Section 3.9 on "Thrust Blocking and Anchorage at Fittings." Figure 21 The last full length laid should be firmly wedged and braced to prevent kicking out under pressure, as seen in Figure 22. (All exposed pipe must be wedged or backfilled, in order to hold it securely in line.) Using a plumb bob over a reference point on the pipe will check creeping when pressure is built up. Figure 22 5.2.1 FILLING THE LINE The line can be slowly filled from any available low-pressure source. The water can be introduced from lines in service through valve connections, by temporary connections to hydrants, to taps made in the new line, or at the connection in the end cap. All such connections, however, should be made at the lowest point in the line, if possible, to help eliminate air entrapment. Where a portion of the line is to be tested and has not yet been tied to the final source, some other source of water must be found. Table 6 shows the approximate volume of water required for filling JM Eagle TMPVC Blue Brute1M, Big Blue T' and Ultra Blue T"pipe. BLUE BRUTE-/BIG BLUE'"/ULTRA BLUE" INSTALLATION GUIDE 43 VOLUME OF WATER REQUIRED a.x.i I PIPE SIZE (inches) C9001C905 PIPE DR 51 41 32.5 25 18 14 4 - - - 0.79 0.73 0.68 6 - - - 1.62 1.51 1.40 8 - - - 2.80 2.60 2.41 10 - - - 4.21 3.91 3.62 12 - - - 5.95 5.54 5.12 14 - - 8.34 8.00 7.44 - 16 - - 10.80 10.34 9.61 - 18 - - 13.56 13.00 12.07 - 20 - - 16.63 15.95 14.82 - 24 - - 23.74 22.74 21.14 - 30 38.38 37.58 36.50 35.00 - - 36 54.98 53.76 52.29 50.12 - - 42 74.22 72.59 70.61 67.68 - - 48 96.72 94.55 92.02 88.18 - - VOLUME OFWATER lREQUIRED I PIPE SIZE (inches) AWWA C909-09 PC 100 Pc 165 PC 235 6 1.70 - 1.69 8 2.93 - 2.90 10 4.41 - 4.37 12 6.24 - 6.18 16 - 11.18 - Table 6 L 44 BLUE BRUTE/BIG BLUE/ULTRA BLUE TM INSTALLATION GUIDE 5.2.2 RELIEVING AIR FROM THE LINE ALL AIR SHOULD BE VENTED FROM ALL HIGH SPOTS IN THE PIPELINE BEFORE MAKING EITHER PRESSURE OR LEAKAGE TESTS. AUTOMATIC AIR RELEASE VALVES ARE RECOMMENDED. Compressed entrapped air causes difficulty in pumping to required pressure for strength tests. Furthermore, a pipeline may leak compressed air when it is actually watertight. If this occurs during a leakage test, it will cause erroneous results. Most importantly, when entrapped air is compressed, it poses a severe explosion hazard and may result in pipe failure and/or injury to property and/ or persons. Don't use PVC for compressed-air systems. 5.3 PRESSURE-STRENGTH TESTS The purpose of a pressure-strength test is to make certain that the line will withstand normal working pressure plus reasonable excesses that may occur. In a properly designed line, excess pressures will be kept to a minimum by the use of automatic relief valves, slow closing and opening valves, slow pump starting and other controls. A test pressure of 25 percent above the normal operating pressure should generally be sufficient, unless the specification calls for greater pressure. Do not build test pressures greater than those specified. This can happen if the pressure is read from a gauge located at a high point in the line. In such cases the actual pressure at low points will be greater and might cause damage to the line. In all cases, it is important that no pressure test, regardless of duration, exceed the marked pressure capacity of the pipe and/or accessories being tested. Doing so might cause damage to the line or shorten the expected life of the system. For more detailed instructions on how to perform installation and pressure testing, please consult ASTM D2774, "Standard Practice for Underground Installation of Thermoplastic Pressure Piping" and/or the appropriate AWWA standards. BLUE BRUTE'"/BIG BLUE"/ULTRA BLUE" INSTALLATION GUIDE 45 5.4 MAKING LEAKAGE TESTS The purpose of a leakage test is to establish that the section of line to be tested-including all joints, fittings, and other appurtenances-will not leak or that the leakage established is within the limits of the applicable leakage allowance. Leakage, if any, is usually involved in joints at saddles, valves, transition fittings and adaptors not usually in pipe joints. Normal operating pressure is usually applied for tests. This should be maintained as constant as possible throughout the testing period. Measurement of the amount of additional water pumped in during the test will provide a measurement of the amount of leakage, if any. In setting up a section of line for testing, air relief valves should be provided. Air trapped in the line during the test will affect test results and can cause damage to the pipeline and/or injury to workers. Generally, the engineer will establish the duration of the test, the allowable leakage, and indicate the appropriate methods and procedures for testing. If not, a two-hour test is recommended and the allowable leakage shall be determined by the following formula: L = (N DIP) / 7400 L is the allowable leakage, in gallons per hour; N is the number of joints in the length of pipeline tested; D is the nominal diameter of the pipe in inches; and P is the average test pressure during the test in pounds per square inch gauge (PSIG). Leakage values determined by the above formula are shown in Table 7. 46 BLUE BRUTE"/BIG BLUE/ULTRA BLUE INSTALLATION GUIDE LEAKAGE ALLOWAN CE GALLONS IPERII.I. JOINTS IJ:I[.1IJ : PIPE SIZE (inches) TEST PRESSURE (psi) 50 100 150 200 225 4 0.38 0.54 0.66 0.76 0.81 6 0.57 0.81 0.99 1.15 1.22 8 0.76 1.08 1.32 1.53 1.62 10 0.96 1.35 1.66 1.91 2.03 12 1.15 1.62 1.99 2.29 2.43 14 1.34 1.89 2.32 2.68 2.84 16 1.53 2.16 2.65 3.06 3.24 18 1.72 2.43 2.98 3.44 3.65 20 1.91 2.70 3.31 3.82 4.05 24 2.29 3.24 3.97 4.59 4.86 30 2.87 4.05 4.97 5.73 6.08 36 3.44 4.86 5.96 6.88 7.30 42 4.01 5.68 6.95 8.03 8.51 48 4.59 6.49 7.94 9.17 9.73 Table 7 Consideration should be given to any valves isolating the test section. Many waterworks valves are not designed for leak-proof operation. Leakage through these valves can distort actual leakage figures. The leakage allowances indicated are intended for municipal water pipe distribution networks, which include numerous valves and fittings. However, JM EagleTM PVC Blue Brute TM, Big Blue1M and Ultra Blue T"Pressure pipe can meet the tighter leakage allowances of NFPA 24, "Standard for Outside Protection (Firelines)." Potable water lines may require disinfecting per AWWA standards. BLUE BRUTE-/BIG BLUET7ULTRA BLUE'" INSTALLATION GUIDE 47 5.5 MAKING REPAIRS TO DAMAGED PIPELINES When pipe has been damaged and repair is required, all damaged material may be replaced in kind or the pipe may be repaired using a repair clamp or other methods authorized by the engineer. If a repair clamp is to be used, the full circle type with opposed bolt line flanges is recommended and should be installed in accordance with the manufacturer's instructions. Gouges that have a depth greater than 10 percent of the wall thickness of the pipe, should be repaired. If the damaged area is localized, a repair clamp may be used. When the damaged area extends beyond a localized area, it is recommended that the damaged section of the pipe be cut out and replaced. In such cases, repair clamps or Dresser-type couplings will be required to join the pipe ends. Other types of couplings may be available. Please consult JM Eagle TMfor acceptability of these other products. NOTE: Trenches and/or casing should be constructed and used in accordance with all applicable state and federal standards to ensure safety. NOTICE TO ALL READERS OF THIS GUIDE: PVC pipe installation may be hazardous to pipe, property and/or people if this guide and/or the recommendations of JM Eagle' are not adhered to fully. JM EagleTM has made every effort to expose all known dangers of misusing PVC pipe in this guide; however, JM EagleTM cannot possibly know or anticipate all situations or outcomes. JM Eagle TMmaintains the position that PVC pipe is the most reliable and safest piping material available. Thus, JM Eagle T'encourages all users of its products to exercise good judgment when installing our products and to consult JM Eagle TMfor additional information when questions or concepts illustrated herein are not fully answered or understood. It is recommended that all users of its products (or people handling) attend training on pipe construction, installation and safety prior to working with its products to ensure safety, knowledge and understanding. Should you need further assistance, please contact JM Eagle'" Product Assurance at 1-800- 621-4404. 48 BLUE BRUTE"/BIG BLUE"/ULTRA BLUE" INSTALLATION GUIDE APPENDIX 1 EMBEDMENT MATERIALS Materials suitable for foundation and embedment are classified in Table A1.1. They include a number of processed materials plus soil types defined according to the Unified Soil Classification System (USCS) in ASTM D2487, "Standard Method for Classification of Soils for Engineering Purposes." Table A1.2 provides recommendations on the installation and use based on class of soil or aggregates and location within the trench. It is important to engineer all materials used in the pipe trench to work together and with the native material surrounding the trench. Class IA Materials: Class IA materials provide the maximum stability and pipe support for a given density because of the angular interlocking of the material particles. With minimum efforts, these materials can be installed at relatively high densities over a wide range of moisture contents. These materials also have excellent drainage characteristics that may aid in the control of water. These soils are often desirable as embedment in rock cuts where water is frequently encountered. On the other hand, when ground water flow is anticipated, consideration should be given to potential migration of fines from adjacent materials into the open graded Class IA materials. Class lB Materials: Class lB materials are produced by mixing Class IA and natural or processed sands to produce a particle-size distribution that minimizes migration from surrounding soils that may contain fines. They are more widely graded than Class IA and thus require more compaction effort to achieve the minimum density specified. When these materials are properly compacted these soils exhibit high stiffness and strength, and depending on the amount of fines, may be relatively free draining. Class II Materials: When Class II materials are compacted, they provide a relatively high level of pipe support. In most respects, they all have the desirable characteristics of Class lB materials when widely graded. However, open-graded groups may allow for migration and the sizes should be checked for compatibility with the native trench materials. Typically, Class II materials consist of rounded particles and are less stable than the angular materials of Class IA and lB unless they are confined and compacted. a BLUE BRUTE"/BIG BLUE"/ULTRA BLUE" INSTALLATION GUIDE 49 Class Ill Materials: These materials provide less support for a given density than Class I or Class II materials. High levels of compaction effort are required if moisture content is not controlled. These materials will provide reasonable support once proper compaction is achieved. Class IV-A Materials: Class IV-A materials must be carefully evaluated before use. The moisture content of the materials must be near optimum to minimize compaction effort and achieve the required density. Properly placed and compacted, these soils can provide reasonable levels of pipe support. However, these materials may not be suitable under high fills, surface applied dynamic loads, or under heavy vibratory compactors and tampers. These materials should be avoided if water conditions in the trench may cause instability and result in uncontrolled water content. 50 BLUE BRUTE'/BIG BLUE/ULTRA BLUE INSTALLATION GUIDE Table A1.1 Description of Material Classification as Defined in ASTM D2321 Percentage Passing Atterberg Coefficients Sieve Sizes Limits Class Type Soil Symbol Description ASTM D2487 1.5 in No.4 No.200 LL PL Un iformity Curvature Group (40 mm) (4.75 mm) (.075 mm) Cu Cc Manufactured Angular, crushed stone or IA Aggregates: None rock, crushed slag, cinders 100% <or = 10% <5% Non open graded, or shell: large void content, Plastic clean contain little or no fines Manufactured, Angular, crushed stone (or Processed other Class IA materials) and lB Aggregates: None stone/sand mixtures with 100% <or = 50% <5% Non dense graded, gradations selected to Plastic clean minimize migration of adjacent soils: contain little to no fines Coarse-Grained Well graded gravels and < 50% of NOfl Soils: clean 3W gravel-sand mixtures: little 100% coarse <5% Plastic > 4 1 to 3 to no fines fraction - Poorly graded gravels and GP gravel-sand mixtures: little <4 <1 or> 3 to no fines SW Well graded sands and gray- <500/ 0 f coarse 1to3 >6 elly sands: little to no fines fraction SP Poorly graded sands and <6 <lor>3 gravelly sands: little to no fines Coarse-Grained Sands and gravels which NOfl Same as Soils: borderline are bordeline between clean 100% varies 5% to 12% Plastic for GW, GP, clean to w/fines and with fines SW, and SP Based on tables found in the Uni-Bell® PVC Pipe Association, "Handbook of PVC Pipe Design and Construction." 01 Table All continued Percentage Passing Sieve Sizes Atterberg Limits Coefficients Class Type Soil Symbol Description 1 5 in No 4 No 200 LL PL Uniformity Curvature Group ASTM D2487 (40 mm) (4.75 mm) (075 mm) Cu Cc Coarse- Silty gravels, > 50% of 0 III Grained Soils GM gravel-sand-silt 100% coarse fraction > 12 /0 t0 < 50/0 <4 or < "A" Line wl Fines mixtures Clayey gravels, GO gravel-sand-clay <7 and > "A" Line mixtures - SM Silty sands, > 50% of >40r< A Line sand-silt mixtures coarse fraction SC Clayey sands, > 7 and> A Line sand-silt mixtures Inorganic silts Fine-Grained and very fine IV-A ML sands, rock flour, silty or clayey fine 100% 100% > 50% <50 <4 or < "A" Line Inorganic sands, silts with slight plasticity Inorganic clays of low to medium CL plasticity, gravely > 7 and > "A" Line clays, sandy clays, silty clays, lean clays Based on tables found in the Uni-BellO PVC Pipe Association, "Handbook of PVC Pipe Design and Construction." 01 Table Al.2 Recommendations for Installation and Use of Soils and Aggregates for Foundation, Embedment, and Backfill Soil Class as Defined in Table A1.1 Class IA Class I Class II Class Ill Class IV-A Do not use where cond- Process materials Obtain geotechnical evalu- tions may cause migration as required to obtain Where hydraulic ation of processed material. of fines from adjacent soil gradation which will gradient exists check May not be suitable under General and loss of pipe support. minimize migration gradation to minimize Do not use where water high earth fills, surface ap- Recommendations Suitable for use as a drain- of adjacent materi- migration. Clean conditions in trench may plied loads and under heavy and Restrictions age blanket and underdrain als. Suitable for use groups suitable for cause instability vibratory compactors and in rock cuts where adjacent as drainage blanket use as drainage blan- tampers. Do not use where material is suitably graded. and underdrain. ket and underdrain. water conditions in trench may cause instability. Suitable as founda- Suitable as foundation Suitable as foundation Suitable as iounua ifl tion and for replacing and for replacing over- Suitable only in undisturbed and for replacing over- tion and for replac- over-excavated d excavated trench bottom condition and where trench excavated and unstable ing over-excavated unstable trench as restricted above. Do is dry., Remove all loose Foundation u a ion trench bottom as restricted and unstable trench bottom as restricted not use in thicknesses material and provide firm, above. Install and compact bottom. Install and above Install and greater than 12 inches uniform trench bottom before in 6-inch maximum layers. compact in 6-inch compact in 6-inch total. Install and corn- bedding is placed. maximum layers. maximum layers pact in 6-inch maximum layers. Based on tables found in the Uni-Bell® PVC Pipe Association, 'Handbook of PVC Pipe Design and Construction." 01 0) Table A1..2 continued Soil Class as Defined in Table A1.1 rd lassIA Class IS Class II Class Ill Class IV-A Suitable as restricted Install and compact Suitable as restricted Suitable only in dry trench Suitable only in dry trench above. Install in 6 in 6 inch maxium above Install and compact conditions. Install and conditions and when optimum inch maximum layers. layers. Level final in 6-inch-maximum la rs compact in 6-inch-max- placement and compaction control Bedding Level final grade by grade by hand. Level final gradeb hand imum layers. Level final is maintained. Install and compact hand. Minimum depth Minimum depth 4 grade by hand. Minimum in 6 inch maximum layers. Level fi- 4 inches (6 inches in inches (6 inches in Minimum depth 4 ' hes (6 inches in rock c ts) u . depth 4 inches (6 inches nal grade by hand. Minimum depth rock cuts). rock cuts). in rock cuts). 4 inches (6 inches in rock cuts). Suitable as restricted Install and compact Suitable as restricted Suitable as restricted Suitable only in dry trench conditions and when optimum above. Install in 6 in 6 inch maximum above. Install and above. Install and Placement and compaction control Ha nch U ing inch maximum layers. Work in around pipe layers. Work in around pipe by hand compact in 6-inch- maximum layers. Work in compact in 6-inch- maximum layers. Work in is nd compact maintained Install and by hand to provide to provide uniform around pipe by hand to around pipe by hand to in 6 inch m layers. Work in around pipe by hand to provide uniform support. support. provide uniform support. provide uniform support. uniform support. Suitable as restricted Install and compact Suitable as restricted Suitable as restricted Suitable as restricted above Install Initial above. Install to a to a minimum of 6 above. Install and compact above. Install and corn- m a and c t t c aminumum of 6 Backfill minimum of 6 inches inches above pipe to a minumum of 6 inches pact to a minumum of 6 9 inches above crown. above pipe crown. crown, above pipe crown. inches above pipe crown. Final Compact as required Compact as required Compact as required by Compact as required by Suitable as restricted above. act as require y e Backfill by the engineer, by the engineer, the engineer, the engineer. ePr?e. Based on tables found in the Uni-BellO PVC Pipe Association, 'Handbook of PVC Pipe Design and Construction". NOTES: NOTES: '1 CITY OF CARLSBAD RECYCLED WATER PHASE 2 PIPELINE EXPANSION SEGMENT No. 18 (PALMER WAY & IMPALA DRIVE) BURTECH PIPELINE, INC OFFICE# (760) 634-2822 ar Merchant/Resident: a part of the City of Carlsbad's ongoing program to improve its water system, ristruction of a new recycled water pipeline is scheduled in your neighborhood. The ristruction will include installation of a new water main along Palmer Way & Impala ive. Parking signs will be posted in advance of construction activities. To minimize tion of time, Burtech Pipeline strives to reduce impact to your community, working rs will be from 7am to 4pm, Monday through Friday. Burtech Pipeline is the Contractor that will be performing the construction for the city and you may call them at the above phone number if you have any questions regarding the project. If you have a moving company scheduled during the construction period please call and inform the Contractor of the date. If you have any concerns which cannot be addressed by the Contractor, you may call the City's Project Inspector . Construction updates will be available on the City of Carlsbad website at www.carlsbadca. nov. Thank you for you cooperation as we work to make a better City of Carlsbad. ATTACHMENT D ATTACHMENT D RISK LEVEL 2 REQUIREMENTS A. Effluent Standards [These requirements are the same as those in the General Permit order.] 1. Narrative - Risk Level 2 dischargers shall comply with the narrative effluent standards listed below: a. Storm water discharges and authorized non-storm water discharges regulated by this General Permit shall not contain a hazardous substance equal to or in excess of reportable quantities established in 40 C.F.R. §§ 117.3 and 302.4, unless a separate NPDES Permit has been issued to regulate those discharges. b. Dischargers shall minimize or prevent pollutants in storm water discharges and authorized non-storm water discharges through the use of controls, structures, and management practices that achieve BAT for toxic and non-conventional pollutants and BCT for conventional pollutants. 2. Numeric - Risk level 2 dischargers are subject to a pH NAL of 6.5-8.5, and a turbidity NAL of 250 NTU. B. Good Site Management "Housekeeping" 1. Risk Level 2 dischargers shall implement good site management (i.e., "housekeeping") measures for construction materials that could potentially be a threat to water quality if discharged. At a minimum, Risk Level 2 dischargers shall implement the following good housekeeping measures: Conduct an inventory of the products used and/or expected to be used and the end products that are produced and/or expected to be produced. This does not include materials and equipment that are designed to be outdoors and exposed to environmental conditions (i.e. poles, equipment pads, cabinets, conductors, insulators, bricks, etc.). Cover and berm loose stockpiled construction materials that are not actively being used (i.e. soil, spoils, aggregate, fly-ash, stucco, hydrated lime, etc.). 2009-0009-DWQ September 2, 2009 ATTACHMENT D Store chemicals in watertight containers (with appropriate secondary containment to prevent any spillage or leakage) or in a storage shed (completely enclosed). Minimize exposure of construction materials to precipitation. This does not include materials and equipment that are designed to be outdoors and exposed to environmental conditions (i.e. poles, equipment pads, cabinets, conductors, insulators, bricks, etc.). Implement BMPs to prevent the off-site tracking of loose construction and landscape materials. 2. Risk Level 2 dischargers shall implement good housekeeping measures for waste management, which, at a minimum, shall consist of the following: Prevent disposal Of any rinse or wash waters or materials on impervious or pervious site surfaces or into the storm drain system. Ensure the containment of sanitation facilities (e.g., portable toilets) to prevent discharges of pollutants to the storm water drainage system or receiving water. Clean or replace sanitation facilities and inspecting them regularly for leaks and spills. Cover waste disposal containers at the end of every business day and during a rain event. Prevent discharges from waste disposal containers to the storm water drainage system or receiving water. Contain and securely protect stockpiled waste material from wind and rain at all times unless actively being used. Implement procedures that effectively address hazardous and non- hazardous spills. Develop a spill response and implementation element of the SWPPP prior to commencement of construction activities. The SWPPP shall require: Equipment and materials for cleanup of spills shall be available on site and that spills and leaks shall be cleaned up immediately and disposed of properly. 2009-0009-DWQ 2 September 2, 2009 ATTACHMENT D ii. Appropriate spill response personnel are assigned and trained. i. Ensure the containment of concrete washout areas and other washout areas that may contain additional pollutants so there is no discharge into the underlying soil and onto the surrounding areas. 3. Risk Level 2 dischargers shall implement good housekeeping for vehicle storage and maintenance, which, at a minimum, shall consist of the following: Prevent oil, grease, or fuel to leak in to the ground, storm drains, or surface waters. Place all equipment or vehicles, which are to be fueled, maintained and stored in a designated area fitted with appropriate BMPs. Clean leaks immediately and disposing of leaked materials properly. 4. Risk Level 2 dischargers shall implement good housekeeping for landscape materials, which, at a minimum, shall consist of the following: Contain stockpiled materials such as mulches and topsoil when they are not actively being used. Contain all fertilizers and other landscape materials when they are not actively being used. Discontinue the application of any erodible landscape material within 2 days before a forecasted rain event or during periods of precipitation. Apply erodible landscape material at quantities and application rates according to manufacture recommendations or based on written specifications by knowledgeable and experienced field personnel. Stack erodible landscape material on pallets and covering or storing such materials when not being used or applied. 5. Risk Level 2 dischargers shall conduct an assessment and create a list of potential pollutant sources and identify any areas of the site where additional BMPs are necessary to reduce or prevent pollutants in storm water discharges and authorized non-storm water discharges. This potential pollutant list shall be kept with the SWPPP and shall identify 2009-0009-DWQ 3 . September 2, 2009 ATTACHMENT D all non-visible pollutants which are known, or should be known, to occur on the construction site. At a minimum, when developing BMPs, Risk Level 2 dischargers shall do the following: Consider the quantity, physical characteristics (e.g., liquid, powder, solid), and locations of each potential pollutant source handled, produced, stored, recycled, or disposed of at the site. Consider the degree to which pollutants associated with those materials may be exposed to and mobilized by contact with storm water. Consider the direct and indirect pathways that pollutants may be exposed to storm water or authorized non-storm water discharges. This shall include an assessment of past spills or leaks, non-storm water discharges, and discharges from adjoining areas. Ensure retention of sampling, visual observation, and inspection records. Ensure effectiveness of existing BMPs to reduce or prevent pollutants in storm water discharges and authorized non-storm water discharges. Risk Level 2 dischargers shall implement good housekeeping measures on the construction site to control the air deposition of site materials and from site operations. Such particulates can include, but are not limited to, sediment, nutrients, trash, metals, bacteria, oil and grease and organics. Additional Risk Level 2 Requirement:. Risk Level 2 dischargers shall document all housekeeping BMPs in the SWPPP and. REAP(s) in accordance with the nature and phase of the construction project... Construction phases at traditional land development projects include Grading and Land Development Phase, Streets and Utilities, or Vertical Construction for traditional land development projects. C. Non-Storm Water Management 1. Risk Level 2 dischargers shall implement measures to control all non- storm water discharges during construction. 2: Risk Level 2 dischargers shall wash vehicles in such a manner as to prevent non-storm water discharges to surface waters or MS4 drainage systems. 20090009-DWQ 4 September 2, 2009 .4f A ATTACHMENT D 3. Risk Level 2 dischargers shall clean streets in such a manner as to prevent unauthorized non-storm water discharges from reaching surface water or MS4 drainage systems. D. Erosion Control Risk Level 2 dischargers shall implement effective wind erosion control. Risk Level 2 dischargers shall provide effective soil cover for inactive' areas and all finished slopes, open space, utility backfill, and completed lots. Risk Level 2 dischargers shall limit the use of plastic materials when more sustainable, environmentally friendly alternatives exist. Where plastic materials are deemed necessary, the discharger shall consider the use of plastic materials resistant to solar degradation. E. Sediment Controls Risk Level 2 dischargers shall establish and maintain effective perimeter controls and stabilize all construction entrances and exits to sufficiently control erosion and sediment discharges from the site. On sites where sediment basins are to be used, Risk Level 2 dischargers shall, at minimum, design sediment basins according to the method provided in CASQA's Construction BMP Guidance Handbook. Additional Risk Level 2 Requirement: Risk Level 2 dischargers shall implement appropriate erosion control BMPs (runoff control and soil stabilization) in conjunction with sediment control BMPs for areas under active 2 construction. Additional Risk Level 2 Requirement: Risk Level 2 dischargers shall apply linear sediment controls along the toe of the slope, face of the slope, and at the grade breaks of exposed slopes to comply with sheet flow lengths3 in accordance with Table 1. Table I -Critical Slope/Sheet Flow Length Combinations Slop!_Percentage_ !_nqt Inactive areas of construction are areas of construction activity that have been disturbed and are not scheduled to be re-disturbed for at least 14 days. 2 Active areas of construction are areas undergoing land surface disturbance. This includes construction activity during the preliminary stage, mass grading stage, streets and utilities stage and the vertical construction stage. Sheet flow length is the length that shallow, low velocity flow travels across a site. 2009-0009-DWQ 5 September 2, 2009 ATTACHMENT D • . toexceed 0-25%20 feet 25-50%15 feet Over 50% 1,0 feet Additional Risk Level 2 Requirement: Risk Level 2 dischargers shall ensure that construction activity traffic to and from the project is limited to entrances and exits that employ effective controls to prevent offsite tracking of sediment. Additional Risk Level 2 Requirement: Risk Level 2 dischargers shall ensure that all storm drain inlets and perimeter controls, runoff control BMPs, and pollutant controls at entrances and exits (e.g. tire washoff locations) are maintained and protected from activities that reduce their effectiveness. Additional Risk Level 2 Requirement: Risk Level 2 dischargers shall inspect on a daily basis all immediate access roads daily. At a minimum daily (when necessary) and prior to any rain event, the discharger shall remove any sediment or other construction activity- related materials that are 'deposited on the roads (by vacuuming or sweeping). Run-on and Run-off Controls Risk Level 2 dischargers shall effectively manage all run-on, all runoff within the site and all runoff that discharges off the site. Run-on from off site shall be directed away from all disturbed areas or shall collectively be in compliance with the effluent limitations in this General Permit. Inspection, Maintenance and Repair Risk Level 2 dischargers shall ensure that all inspection, maintenance repair and sampling activities at the project location shall be performed or supervised by a Qualified SWPPP Practitioner (QSP) representing the discharger. The QSP may delegate any or all of these activities to an employee appropriately trained to do the task(s). Risk Level 2 dischargers shall perform weekly inspections and observations, and at least once each 24-hour period during extended storm events, to identify and record BMPs that need maintenance to operate effectively, that have failed, or that could fail to operate as intended. Inspectors shall be the QSP or be trained by the QSP. Upon identifying failures or other shortcomings, as directed by the QSP, Risk Level 2 dischargers shall begin implementing repairs or 2009-0009-DWQ • 6 September 2, 2009 6 ATTACHMENT D design changes to BMPs within 72 hours of identification and complete the changes as soon as possible. For each inspection required, Risk Level 2 dischargers shall complete an inspection checklist, using a form provided by the State Water Board or Regional Water Board or in an alternative format. Risk Level 2 dischargers shall ensure that checklists shall remain onsite with the SWPPP and at a minimum, shall include: Inspection date and date the inspection report was written. Weather information, including presence or absence of precipitation, 'estimate of beginning of qualifying storm event, duration of event, time elapsed since last storm, and approximate amount of rainfall in inches. Site information, including stage of construction, activities completed, and approximate area of the site exposed. A description of any BMPs evaluated and any deficiencies noted. If the construction site is safely accessible during inclement weather, list the observations of all BMPs: erosion controls, sediment controls, chemical and waste controls, and non-storm water. controls. Otherwise, list the results of visual inspections at all relevant outfalls, discharge points, downstream locations and any projected maintenance activities. Report the presence of noticeable odors or of any visible sheen on the surface of any discharges. Any corrective actions required, including any necessary changes to the SWPPP and the associated implementation dates. Photographs taken during the inspection, if any. I. Inspector's name, title, and signature. H. Rain Event Action Plan 1. Additional Risk Level 2 Requirement: The discharger shall ensure a QSP develop a Rain Event Action Plan (REAP) 48 hours prior to any likely precipitation event. A likely precipitation event is any weather pattern that is forecast to have a 50% or greater probability of producing precipitation in the project area. The discharger shall 2009-0009-DWQ 7 September 2, 2009 ATTACHMENT D ensure a QSP obtain a printed copy of precipitation forecast information from the National Weather Service Forecast Office (e.g., by entering the zip code of the project's location at http://www.srh.noaa.qov/forecast). 2. Additional Risk Level 2 Requirement The discharger shall ensure a QSP develop the REAPs for all phases of construction (i.e., Grading and Land Development, Streets and Utilities, Vertical Construction, Final Landscaping and Site Stabilization). 3. Additional Risk Level 2 Requirement: The discharger shall ensure a QSP ensure that the REAP include, at a minimum, the following site information: Site Address Calculated Risk Level (2 or 3) Site Storm Water Manager Information including the name, company, and 24-hour emergency telephone number Erosion and Sediment Control Provider information including the name, company, and 24-hour emergency telephone number Storm Water Sampling Agent information including the name, company, and 24-hour emergency telephone number 4. Additional Risk Level 2 Requirement: The discharger shall ensure a QSP include in the REAP, at a minimum, the following project phase information: Activities associated with each construction phase Trades active on the construction site during each construction phase Trade contractor information Suggested actions for each project phase 5. Additional Risk Level 2 Requirement: The discharger shall ensure a QSP develop additional REAPs for project sites where construction activities are indefinitely halted or postponed (Inactive Construction). At a minimum, Inactive Construction REAPs must include: Site Address Calculated Risk Level (2 or 3) Site Storm Water Manager Information including the name, company, and 24-hour emergency telephone number Erosion and Sediment Control Provider information including the name, company, and 24-hour emergency telephone number Storm Water Sampling Agent information including the name, company, and 24-hour emergency telephone number 2009-0009-DWQ 8 September 2, 2009 7 Additional Risk Laval 2 Rrniirmnt: Thc dishrnr hiII nsiir a ATTACHMENT D Trades active on site during Inactive Construction Trade contractor information Suggested actions for inactive construction sites 6. Additional Risk Level 2 Requirement: The discharger shall ensure a QSP begin implementation and make the REAP available onsite no later than 24 hours prior to the likely precipitation event. J ATTACHMENT D I. Risk Level 2 Monitoring and Reporting Requirement s Table 2- Summary of Monitoring Requireme n t s Visual Inspections Sample Collection Quarterly Pre-storm Risk Non- Event Daily Post Storm Receiving Baseline REAP Level storm Storm Storm Water Water Water BMP Discharge Discharge 2 X X X X X X 1. Construction Site Monitoring Program R e q u i r e m e n t s Pursuant to Water Code Sections 13383 a n d 1 3 2 6 7 , a l l d i s c h a r g e r s subject to this General Permit shall develop a n d i m p l e m e n t a written site-specific Construction Site Mon i t o r i n g P r o g r a m ( C S M P ) in accordance with the requirements of this S e c t i o n . T h e C S M P shall include all monitoring procedures an d i n s t r u c t i o n s , l o c a t i o n maps, forms, and checklists as required in t h i s s e c t i o n . T h e C S M P shall be developed prior to the commence m e n t o f c o n s t r u c t i o n activities, and revised as necessary to reflec t p r o j e c t r e v i s i o n s . T h e CSMP shall be a part of the Storm Water P o l l u t i o n P r e v e n t i o n P l a n (SWPPP), included as an appendix or se p a r a t e S W P P P c h a p t e r . Existing dischargers registered under the S t a t e W a t e r B o a r d O r d e r No. 99-08-DWQ shall make and implemen t n e c e s s a r y r e v i s i o n s t o their Monitoring Program to reflect the c h a n g e s i n t h i s G e n e r a l Permit in a timely manner, but no later tha n J u l y 1 , 2 0 1 0 . E x i s t i n g dischargers shall continue to implement the i r e x i s t i n g M o n i t o r i n g Programs in compliance with State Water B o a r d O r d e r N o . 9 9 - 0 8 - DWQ until the necessary revisions are comp l e t e d a c c o r d i n g t o t h e schedule above. When a change of ownership occurs for all or a n y p o r t i o n o f t h e construction site prior to completion or fina l s t a b i l i z a t i o n , t h e n e w discharger shall comply with these requirem e n t s a s o f t h e d a t e t h e ownership change occurs. 2. Objectives The CSMP shall be developed and impleme n t e d t o a d d r e s s t h e following objectives: 2009-0009-DWQ 10 September 2, 2009 } ATTACHMENT D To demonstrate that the site is in compliance with the Discharge Prohibitions and applicable Numeric Action Levels (NALs)/Numer i c Effluent Limitations (NELs) of this General Permit. To determine whether non-visible pollutants are present at the construction site and are causing or contributing to exceedances o f water quality objectives. To determine whether immediate corrective actions, additional B e s t Management Practice (BMP) implementation, or SWPPP revisions re necessary to reduce pollutants in storm water discharges an d authorized non-storm water discharges. To determine whether BMPs included in the SWPPP/Rain Event Action Plan (REAP) are effective in preventing or reducing pollutants in storm water discharges and authorized non-storm water discharges. 3. Risk Level 2— Visual Monitoring (Inspection) Requireme n t s f o r Qualifying Rain Events Risk Level 2 dischargers shall visually observe (inspect) storm water discharges at all discharge locations within two business days (48 hours) after each qualifying rain event. Risk Level 2 dischargers shall visually observe (inspect) the discharge of stored or contained storm water that is derived from and discharged subsequent to a qualifying rain event producing precipitation of 1/2 inch or more at the time of discharge. Stored or contained storm water that will likely discharge after operating hours due to anticipated precipitation shall be observed prior to th e discharge during operating hours. Risk Level 2 dischargers shall conduct visual observations (inspections) during business hours only. Risk Level 2 dischargers shall record the time, date and rain gauge reading of all qualifying rain events. Within 2 business days (48 hours) prior to each qualifying rain event, Risk Level 2 dischargers shall visually observe (inspect): i. all storm water drainage areas to identify any spills, leaks, o r uncontrolled pollutant sources. If needed, the discharger shall implement appropriate corrective actions. 2009-0009-DWQ 11 September 2, 2009 ATTACHMENT D all BMPs to identify whether they have been properly implemented in accordance with the SWPPP/REAP. If needed, the discharger shall implement appropriate corrective actions. any storm water storage and containment areas to detect leaks and ensure maintenance of adequate freeboard. f. For the visual observations (inspections) described in c.i a n d c i i i above, Risk Level 2 dischargers shall observe the presence o r absence of floating and suspended materials, a sheen on the surface, discolorations, turbidity, odors, and source(s) of any observed pollutants. g. Within two business days (48 hours) after each qualifying r a i n event, Risk Level 2 dischargers shall conduct post rain event visua l observations (inspections) to (1) identify whether BMPs were adequately designed, implemented, and effective, and (2) ide n t i f y additional BMPs and revise the SWPPP accordingly. h. Risk Level 2 dischargers shall maintain on-site records of a l l v i s u a l observations (inspections), personnel performing the observations, observation dates, weather conditions, locations observed, and corrective actions taken in response to the observations. 4. Risk Level 2— Water Quality Sampling and Analysis Risk Level 2 dischargers shall collect storm water grab samples from sampling locations, as defined in Section 1.5. The storm w a t e r grab sample(s) obtained shall be representative of the flow and characteristics of the discharge. At minimum, Risk Level 2 dischargers shall collect 3 samples p e r day of the qualifying event. Risk Level 2 dischargers shall ensure that the grab samples collected of stored or contained storm water are from discharge s subsequent to a qualifying rain event (producing precipitation of 1/2 inch or more at the time of discharge). Storm Water Effluent Monitoring Requirements Risk Level 2 dischargers shall analyze their effluent samples for: i. pH and turbidity. -'I 2009-0009-DWQ 12 September 2, 2009 ATTACHMENT D ii. Any additional parameters for which monitoring is required by the Regional Water Board. 5. Risk Level 2— Storm Water Discharge Water Quality Sam p l i n g Locations Effluent Sampling Locations Risk Level 2 dischargers shall perform sampling and analysis of storm water discharges to characterize discharges associated w i t h construction activity from the entire project disturbed area. Risk Level 2 dischargers shall collect effluent samples at all discharge points where storm water is discharged off-site. Risk Level 2 dischargers shall ensure that storm water discharge collected and observed represent4 the effluent in each drainage area based on visual observation of the water and upstream conditions. Risk Level 2 dischargers shall monitor and report site run-on from surrounding areas if there is reason to believe run-on may contribute to an exceedance of NALs or NELs. Risk Level 2 dischargers who deploy an ATS on their site, or a portion on their site, shall collect ATS effluent samples and measurements from the discharge pipe or another location representative of the nature of the discharge. 1. Risk Level 2 dischargers shall select analytical test methods from the list provided in Table 3 below. g. All storm water sample collection preservation and handling sh a l l be conducted in accordance with Section 1.7 "Storm Water Samp l e Collection and Handling Instructions" below. 6. Risk Level 2— Visual Observation and Sample Collection Exemptions a. Risk Level 2 dischargers shall be prepared to collect samples and conduct visual observation (inspections) until the minimum requirements of Sections 1.3 and 1.4 above are completed. Risk For example, if there has been concrete work recently in an area, or dryw a l l s c r a p i s e x p o s e d t o t h e r a i n , a pH sample shall be taken of drainage from the relevant work area. S i m i l a r l y , i f s e d i m e n t l a d e n w a t e r i s flowing through some parts of a silt fence, samples shall be taken of t h e s e d i m e n t - l a d e n w a t e r e v e n i f m o s t water flowing through the fence is clear. 2009-0009-DWQ 13 September 2, 2009 ATTACHMENT 0 Level 2 dischargers are not required to physically collect samples or conduct visual observation (inspections) underthe following conditions: During dangerous weather conditions such as flooding and electrical storms. Outside of scheduled site business hours. b. If no required samples or visual observation (inspections) are collected due to these exceptions, Risk Level 2 dischargers shall include an explanation in their SWPPP and in the Annual Report documenting why the sampling or visual observation (inspection s ) were not conducted. 7. Risk Level 2— Storm Water Sample Collection and Hand l i n g Instructions Risk Level 2 dischargers shall refer to Table 3 below for test methods, detection limits, and reporting units. Risk Level 2 dischargers shall ensure that testing laboratories will receive samples within 48 hours of the physical sampling (unless otherwise required by the laboratory), and shall use only the sample containers provided by the laboratory to collect and store samples. Risk Level 2 dischargers shall designate and train personnel to collect, maintain, and ship samples in accordance with the Surfac e Water Ambient Monitoring Program's (SWAMP) 2008 Quality Assurance Program Plan (QAPrP).5 8. Risk Level 2— Monitoring Methods a. Risk Level 2 dischargers shall include a description of the follow i n g items in the CSMP: Visual observation locations, visual observation procedures, and visual observation follow-up and tracking procedures. Sampling locations, and sample collection and handling procedures. This shall include detailed procedures for sample Additional information regarding SWAMP's QAPrP and QAMP can b e f o u n d a t http:llwww.waterboards.ca.pov/water issues/proQrams/swamp/. QAPrP.http://www.waterboards.ca.cov/water issuesIpropramsIswamidocsIpaøøIswamp gapD master090 108a.pdf. QAMP: http://www.waterboards.ca.cov/water issuesløroqrams/swamp/gamp.shtml. 2009-0009-DWQ 14 September 2, 2009 ATTACHMENT D 10. Risk Level 2 - Non-Storm Water Discharge Monitoring Requirements a. Visual Monitoring Requirements: Risk Level 2 dischargers shall visually observe (inspect) each drainage area for the presence of (or indications of prior) unauthorized and authorized non-storm water discharges and their sources. Risk Level 2 dischargers shall conduct one visual observation (inspection) quarterly in each of the following periods: January- March, April-June, July-September, and October-December. Visual observation (inspections) are only required during daylight hours (sunrise to sunset). Risk Level 2 dischargers shall ensure that visual observations (inspections) document the presence or evidence of any non- storm water discharge (authorized or unauthorized), pollutant characteristics (floating and suspended material, sheen, discoloration, turbidity, odor, etc.), and source. Risk Level 2 dischargers shall maintain on-site records indicating the personnel performing the visual observation (inspections), the dates and approximate time each drainage area and non-storm water discharge was observed, and the response taken to eliminate unauthorized non-storm water discharges and to reduce or prevent pollutants from contacting non-storm water discharges. b. Effluent Sampling Locations: Risk Level 2 dischargers shall sample effluent at all discharge points where non-storm water and/or authorized non-storm water is discharged off-site. Risk Level 2 dischargers shall send all non-storm water sample analyses to a laboratory certified for such analyses by the State Department of Health Services. Risk Level 2 dischargers shall monitor and report run-on from surrounding areas if there is reason to believe run-on may contribute to an exceedance of NALS. 11. Risk Level 2 - Non-Visible Pollutant Monitoring Requirements 2009-0009-DWQ 16 September 2, 2009 ATTACHMENT D Risk Level 2 dischargers shall collect one or more samples during any breach, malfunction, leakage, or spill observed during a visual inspection which could result in the discharge of pollutants to surface waters that would not be visually detectable in storm water. Risk Level 2 dischargers shall ensure that water samples are large enough to characterize the site conditions. Risk Level 2 dischargers shall collect samples at all discharge locations that can be safety accessed. Risk Level 2 dischargers shall collect samples during the first two hours of discharge from rain events that occur during business hours and which generate runoff. Risk Level 2 dischargers shall analyze samples for all non-visible pollutant parameters (if applicable) - parameters indicating the presence of pollutants identified in the pollutant source assessment required (Risk Level 2 dischargers shall modify their CSMPs to address these additional parameters in accordance with any updated SWPPP pollutant source assessment). Risk Level 2 dischargers shall collect a, sample of storm water that has not come in contact with the disturbed soil or the materials stored or used on-site (uncontaminated sample) for comparison with the discharge sample. Risk Level 2 dischargers shall compare the uncontaminated sample to the samples of discharge using field analysis or through laboratory analysis.6 Risk Level 2 dischargers shall keep all field /or analytical data in the SWPPP document. 12. Risk Level 2 - Watershed Monitoring Option Risk Level 2 dischargers who are part of a qualified regional watershed-based monitoring program may be eligible for relief from the requirements in Sections 1.5. The Regional Water Board may approve proposals to substitute an acceptable watershed-based monitoring program by determining if the watershed-based monitoring program 6 For laboratory analysis, all sampling, sample preservation, and analyses must be conducted according to test procedures under 40 CFR Part 136. Field discharge samples shall be collected and analyzed according to the specifications of the manufacturer of the sampling devices employed. 2009-0009-DWQ 17 September 2, 2009 ATTACHMENT D will provide substantially similar monitoring information in evaluating discharger compliance with the requirements of this General Permit. Risk Level 2— Particle Size Analysis for Project Risk Justification Risk Level 2 dischargers justifying an alternative project risk shall report a soil particle size analysis used to determine the RUSLE K-Factor. ASTM D-422 (Standard Test Method for Particle-Size Analysis of Soils), as revised, shall be used to determine the percentages of sand, very fine sand, silt, and clay on the site. Risk Level 2— Records Risk Level 2 dischargers shall retain records of all storm water monitoring information and copies of all reports (including Annual Reports) for a period of at least three years. Risk Level 2 dischargers shall retain all records on-site while construction is ongoing. These records include: The date, place, time of facility inspections, sampling, visual observation (inspections), and/or measurements, including precipitation. The individual(s) who performed the facility inspections, sampling, visual observation (inspections), and or measurements. The date and approximate time of analyses. The individual(s) who performed the analyses. A summary of all analytical results from the last three years, the method detection limits and reporting units, the analytical techniques or methods used, and the chain of custody forms. Rain gauge readings from site inspections; Quality assurance/quality control records and results. Non-storm water discharge inspections and visual observation (inspections) and storm water discharge visual observation records (see Sections 1.3 and 1.10 above). Visual observation and sample collection exception records (see Section 1.6 above). 2009-0009-DWQ 18 September 2, 2009 ATTACHMENT D j. The records of any corrective actions and follow-up activities that resulted from analytical results, visual observation (inspections), or inspections. 15. Risk Level 2— NAL Exceedance Report In the event that any effluent sample exceeds an applicable NAL, Risk Level 2 dischargers shall electronically submit all storm event sampling results to the State Water Board no later than 10 days after the conclusion of the storm event. The Regional Boards have the authority to require the submittal of an NAL Exceedance Report. Risk Level 2 dischargers shall certify each NAL Exceedance Report in accordance with the Special Provisions for Construction Activity. Risk Level 2 dischargers shall retain an electronic or paper copy of each NAL Exceedance Report for a minimum of three years after the date the annual report is filed. Risk Level 2 dischargers shall include in the NAL Exceedance Report: The analytical method(s), method reporting unit(s), and method detection limit(s) of each analytical parameter (analytical results that are less than the method detection limit shall be reported as "less than the method detection limit"). The date, place, time of sampling, visual observation (inspections), and/or measurements, including precipitation. A description of the current BMPs associated with the effluent sample that exceeded the NAL and the proposed corrective actions taken. 2009-0009-DWQ 19 September 2, 2009 ATTACHMENT D Table 3— Risk Level 2 Test Methods, Detection Limits. Reoortina Units and Aonlicable NALs/NLs Parameter Test Method I Discharge T Min Repörting Numeric Action Protocol Type Detection Units Level Limit pH Field test with calibrated lower NAL - 6.5 portable Risk Level 2 0.2 pH units upper NAL = 8.5 instrument Discharges Turbidity EPA 0180.1 Risk Level 2 and/or field test Discharges with calibrated other than 1 NTU 250 NTU portable ATS instrument For ATS discharges 1 NTU N/A 2009-0009-DWQ 20 September 2, 2009 U,ul~[an Materials Company Western Division April 902015 Sealright Paving .9053 Olive Dr .• Spring Valley, Ca 91977 Attn:Monique Vasquez . . Email:srpestimating@sbcglobal.com ., Project: . Recycled Water Phase 3-City of Carlsbad Gentlepersons: This is to certify that we will furnish asphalt-paving material for the above - referenced project to comply-With Standard Specification for Public Works Construction Section 203-6.5.4. (Sec 400 Type Ill & Sec 203) per the 2013 supplement to Greenbook Asphalt Concrete. Our Submittal #38741 (Carroll Canyon) #38742 (Otay) Mix: Type Ill C2 The Asphalt Cement will conform to PG64-10 for Performance Grade. Typically our HVEEM for Asphalt Concrete out of our Carroll Canyon 83 146 +1-2 Otay B3 150+1-2 Carroll Canyon C2 143 +/-2 Otay C2 149 +/-2 Carroll Canyon E 141 +/-2 Otay E 148+1-2 The following table summarizes additional information supporting our mix design. Aggregate Properties Test California Test . Carroll Canyon % Crushed Particle CT 205 Coarse = 98% Fine = 95% LA Rattler, Loss@ 500 Rev. CT 211 3/4" (Method B): 15.7% 1/2" (Method B): 17.2% 3/8" (Method C): 20.2% Cleanness Value CT 227 86 (3/4") I 81 (1/2") 1 79 (3/8") San Diego Regional Quality Control Department :10051 Black Mountain Rd San Diego, Ca 92126. Phone: 858-547-4981 Fax:858-547-9056 Sand Equivalent CT 217 65 Kc &Kf Factors CT 303 1.1 Asphalt Concrete Properties Mix Design California Test 3/4" Mix 1/2" Mix 3/8" Mix S-value .(Hveem) . CT 366 40 39 35 Air Voids . 4.3% 4.3% 4.2% Swell (mm) . CT 305 0.001 .0.001 0.001 Moisture Vapor Susceptibility CT 307 34 33 31 Aggregate_Pro perties Test-'California Test ..Otay- %_Crushed. Particle CT 205 Coarse 98% __J_Fine =_95% LA Rattler, Loss @ 500 Rev. Cr 211 .. 3/4" (Method B): 15.7% . 1/2" (Method B): 17.2% 3/8" (Method C); 20.2% Cleanness Value CT227 86(3/4") _81__(1/2")__I_79(3/8") SandEquivalent CT 217 62- Kc&Kf Factors . CT 303 1.1 Asphalt Concrete Properties Mix. Design California Test 3/4" Mix 1/2"Mix US" Mix Svalue . CT 366 41 37 35 Air Voids 4.4% 4.-4% . 4.394 Swell(mm) CT 305 .0.001 0.001 . 0.001 moisture vapor Susceptibility . 34 32 31 Sincerely, . QC.Technical- Services . . . . . . .. . .. . . ME/SB . . . . . . ... cc: Carroll Canyon & Otay *please note: For this Project Only **NOT VALID IF ALTERED" cc: Carroll Canyon . NOTETOTHECONTRACTOR: VULCAN MATERIALS COMPANY will not be responsible if the contractor or his representative, atthe time of-delivery, altersor orders a mix other than those covered in the above certification. Vulcan Materials Company cannot guarantee the mix characteristics if Used outside the normalplacement specifications. . San. Diego Regional Quality Control Department - 10051 Black Mountain Rd San Diego, Ca 92126 Phone: 858-5474981 Fax: 858-547-9056 Location:] Otay HMA Plant I Mix besign#:I 38742-1 _________ SELTEC 1111irna i Customer: SEALRIGI.fr PAVING jMlx besign bate:! 4/9/2015 MASS MateraIs Company Monique L Fox, ffJ (619) 465-7490 I. Project LIne 1 Recycled Water Ph 3 Projcct S 400 Type 9 R20 I k!ltGrade:I PG 64 - 10 ____ I AG.G Type:!. I SMARA:! 91,37-0035 FIU.EP 0 RECYCLE 380 LBS 3/4" 0 LBS 1/2" 361 LBS 3/8" 361 LBS Rock busti 456 LBSj SANb 342 LBS 1 j L LLusci [jj Use] iPoss[usi L1useI passfs1 [LuseI Total 1 - L1_s 100.0 0.0 100.0 20.0 100.0 0.0 100.0 19.0 100.0 19.0 100.) 24.0 100.0 18.0 100.01 1000 00 10D.0 200 1000 00 1000 19.0 1000 190 100.0 240 100.0 18.0 I 1000! I .,l j I1-1/2 (378) 1000 00 1000 2001000 0.0 100.0 19.0 100.0 19.0 1W.0 24.0 1000 180 I 1000! 11 25 970 00 1000200 870 00 1000 190 1000 190 1000240 1000 180 I 1000! 0I1pII3_(!9O) 840 0.0 100.0 20.0 19.0 0.0 MO 14.3 100.0 19.0 100.0 24.0 10D.0 MO I 95 4 [95 100JI1/2" (12 5)1 68.0 0.0 97.0 19.4 5.0 0.0 5.0 1.0 95.0 18.1 100.0 24.0 100.0 18.0 F 80.41 i1i!c?J 3/8" -. (9.5)1 47.0 0.0 71.0 14.2 2.0 0.0 30 0.6 150 2.9 95.0 22.8 97.0 17.5 I 57.91 67 380 00 530106 10 00 20 04 40 08 640154 870157 I 4281 L3!IL!J8 (236)1 210 00 42.0 6.4 1.0 00 2.0 04 2.0 04 41.0 9.9 72.0 13.0 I {:ff.JJ6 (118)j 160 00 330 66 10 00 10 02 10 02 270 65 480 86 1 221! rii'130J!#30 (060)1 100 00 200 40 10 00 10 02 10 02 220 53 250 45 I 142! Eiii1I.q (co) 70 00 130 26 10 00 10 02 10 02 110 26 60 11 I 671 [j]t.!P(oi)1 5.6 0.0 8.5 1.7 1.0 0.0 1.0 0.2 1.0 0.2 8.7 2.1 3.0 0.5 I 4.71 EiLZJ?00475)1 PAP AC% 5.8% ''° -'- I 5•31 % • 100% AGG KM of Cembned Aggregate----1.10 • • -'i,' -"- I 51 ' Plus SURFACE AREA: 26.3 • • • - 951 % Aggregate Weight Per TON 1001 Los Batch WT: I 20001 LOS Laboratory Manager SAND 17.3 346 Rack bust 23.1 462 8° 18.3 365 1/2" 18.3 365 3/4N 0.0 0 RECYCLE 19.2 385 FILLER 0.0 0 Asphàl+ 3.8 77 TOTAL 100.0 2000 ELTEC Percent I Muss BIN#1 32.5 650 BIN#2 26.8 536 BZN3 16.3 325 eIN#4 0.0 0 BIN#5 0.0 0 RECYCLE 19.1 383 FILLER 1.0 19 Asphalt 4.3 87 TOTAL 99.9 2.000 Location:1 Carroll Canyon I Mix Design#:I 38741-1 UuIcun Customer: SEALRIGI-rr PAVING : [ix besign bote:l 4/9/2015 Materials Company ____ A Monique -Fax 1(619) 4657490 ProjectL4j Recycled Water Ph 3 • TTypa v 54O0 nV~~C2 10420 ipt.6rod!.i PG 64 - 10. I AGG Type:! A I 5MAR41 91-37-0029 1. 1% 20%J osi 0% 17% 28% 34% FILLER REC BIN#5 BIN#4 BIN#3 BIN#2 BIN#1 Sieve Size . •• 1&9 LBS 378 1.8$] 0 LBS 0 LBS 321 LBS 529 LBS 631.8$ pjng ri [JIJ ii riii se i :iU"J Total nJxjjEI($I) 100.0 1.0 100.0 20.0 100.0 0.0 100.0 0.0 100.0 17.0 100.0 28.0 100.0 340 100.01 1_J?L? 5OP) 100.0 1.0 100.0 20.0 100.0 0.0 100.0 0.0 100.0 17.0 100.0 28.0 100.0 340 I 100.01 1, _Ib1 (37.8)! 1000 10 1000 200 1000 00 1000 00 1000 170 1000280 1000340 I 10001 Li1T._1i! 1000 10 1000 200 1000 00 850 00 1000 170 1000 280 1000 340 I 10001 1 100110 .HL4.. (190)1 1000 140 1000 200 1000 00 70 00 83.0 14.1 1000 280 1000 34.0 I 97 ii ii1i00]I!J? (125)1 100.0 1.0 97.0 19.4 98.0 0.0 I.Or 0.0 21.0 3.6 96.0 26.9 100.0 34.0 I 84.81 ELiL 100.0 1.0 71.0 14.2 71.0 0.0 1.0 0.0 1.0 0.2 32.0 .9.0 100.0 34.0. I 58.31 L50JE)!#4 (4.75)1. 1000 1.0 53.10 1.0 .6 53.0 00 1.0 00 1.0 0.2 2.0 0.6 870 29.6 1000 10 420 84 420 00 00 00 10 02 10 03 570194 I 2921 L.iEiI_RL 990 10 330 66 350 00 00 00 00 00 00 00 430146 I 2221 980 10 200 40 200 00 00 00 00 00 00 00 270 92 I 1421 :L2 JQ30)I 950 10 130 26 130 00 00 00 00 00 00 00 160 54 I 90J . :Ii JO 15)1 900 09 85 17 85 00 00 00 00 00 00 00 80 27 I 531 lrjicoTa1 RAP AC% 58% xbesign NOteS - % Asphalt -Outside- 5 % + 100% AGG KM of Combined Aggregute----1.10 .: % Asphalt -Inside- f Pius SURFACE AREA: 28.4 . . .. - . . . -94-51.% Aggregate Weight Per TON F 11011.85 Batch WT: I 20001 LBS - - California . Commercial . . . . . . Asphalt, LLC . .• Asphalt Concrete Conformance Report TO: SEALRIGHT AITN: MONIQUE FROM: CHRIS SPARKS DATE: 4/10/2015 . CONTRACT:. RECYCLED WATER PHASE III ;. ..• . SALES QUOTE # 150658 . . . JOB #: . . . CCA,LLC: CARROLL CANYON ... ASPHALT CONCRETE MIX DESIGN . . .• • . Standard Specifications for Public Works Construction . . Green Book Section 203, Table 203-6.4.3 (A) 1/2". C2-Dense Medium Mix # 12T1C2 Aggregate Materials. %Used Hanson 3/4" 0% Hanson lIT' 17% Hanson 3/8" 32% Hanson R.D. 28% Otay . . Sand 8% CCA Recycle. 15% Combined Gradation Specification Green Book 1/211C2 Dense Med. 100% Sieve Size 1" . 25MM 100 100 100 100 100 . 100 100 100 3/4" .19MM 94 100 100 100 100 100 100 100 1/2" 12.5MM 23 83 100 100 100 96 97 95-100 3/8" . 9.5MM 9 29 91 100 100 88 83 72-88 #4 475MM 7 .7 19 100 98 67 53 . 46-60 #8 .2.36104 5 5 5 73 91 52 .38 28-42 #16 1 1. .3 .50 . 76 39 27 #30 : 600UM 0 41 . 49 29 20 15-27 #50 300UM 0 31 22 19 13 10-20 #100 0 16 8 13 1200.(Wash) 75UM 0 •• 11 4 1 8.5 4.7 2-7 C.V. - Cleanliness Value .86 . 84 .77 . . . 65 Mm. S.E. - Sand Equivalent CA 217 . 64 77 63 % Crushed 98.7 CA 205 . 25 Mm. Moisture Vapor 34 . CA 307 . 25 Mm. Stripping None CA 302 . Not Specified LA Rattler @100 Rev. @500 Rev. 3.0% 15.0% CA 211 . 15 Max. 52 Max. Swell 0.015 CA 305 . . . 0.030 Max. Hveem Density 147.0 CA 366 Max. Theo. 152.7 Voids % 3.8 _______ _____________ Hveem Stability 40 CA 366 33 Mm Recommended use of 5.8% PG 64-10 Asphalt Oil by Dry Weight of Aggregate (DWA) Note: The maximum density should be verified on the date of actual production or when test strip is placed. *Ajr vnidc vRb1e so re. nnt tn he. ueil ntance t'tri ten ui iw ('trepn Rnnk e,-tinn n i - ri 4 1. California Commercial Asphalt, LLC Asphalt Concrete Conformance Report TO: SEALRIGHT ATFN: MONIQUE FROM: CHRIS SPARKS DATE: 4t10/2015 CONTRACT: RECYCLED WATER PHASE IN SALES QUOTE #: 150658 JOB #: CCA,LLC: MIRAMAR PLANT ASPHALT CONCRETE MIX DESIGN . . Standard Specifications for Public Works Construction Green Book Section 203-6 1/2" Type C2 Dense Medium - Mix # 12T1C2 Aggregate Materials. %Used Hanson Bin #4 . 0% Hanson Bin #3. 15% Hanson Bin #2 37% Hanson Bin #1. 32% M.F. 1% CCA Recycle, 15% Combined Specification Green Green Book 1/2"TypeC2 100% Sieve Size 1" 25Ml'4 100 100 100 100 100 100 .100 3/4" 191v11'vl 88 100 100 100 100 100 100 100 1/2" 12.5MM 11 87 100 . 100 100 98 98 . 95-100 3/8" 9.5MM 3 20 92 100 100 86 83 72-88 #4 435MM 1 2 23 100 100 68 . 52 46-60 #8 . .2.36MM 0 2 4 . :78 100 58 36 28-42 #16 0 0 2 57 100 39 26 #30 600UM 0 1 40 100 24 18 15-27 #50 300UM 0 0 27 100 .19 . 12 10-20 #100 0 16 99 12 8 #200 (Wash) 75UM 0 10 99 . .8.5 5.5 2-7 C.V. - Cleanliness Value 79 . 81 79 . . S.E. - Sand Equivalent CA 217 . 81 81 45 Mm. % Crushed 98.7 CA 205 25 Mm. Moisture Vapor 34 CA 307 25 Mm. Stripping None CA 302 25% Max. LA Rattler @ 100 Rev. @500 Rev. 3.0% 15.00/c CA 211 15 Max. 52 Max. Swell 0.016 CA 305 0.030 Max. Hveem Density 146.5 CA 366 Max. Theo 152.7 Voids %' 4.0 Hveem Stability . 41 CA 366 1 1 35 Mm. Recommended use of 5.60/a PG 64-10 Asphalt Oil by Dry Weight of Aggregate (DWA) Note: The maximum density should be verified on the date of actual production or when the test strip is placed. *Air voidvalues are not to be used as acceptance criteria per Green Book section 203-6.4.1. Michael Bailey From: Donnie Purscelley <donnie@burtechpipeline.com> Sent: Monday, April 27, 2015 8:55 AM To: Michael Bailey Subject: Carlsbad Recycled Water Phase 3 - Schedule Mike, Our schedule will go as follows: 5/4/15 - 5/8/15 Mobilize Layout Pothole Deliver Materials 5/10/15-5/14/15 Start excavation & installing pipe 5/18/15 -5/22/15 Test new installations Pave Cleanup Be Well, Donnie Purscelley I Project Manager Burtech Pipeline, Inc. I 102 Second Street, Encinitas, CA 92024 Ph. (760) 634-2822 I Fax (760) 634-5105 I Cell (760) 335-8659 donnie@burtechpipeline.com Crry OF CARLSBAD SHOP DRAWING REVIEW The approval by the Engineer of any shop or woddng drawing (or of any drawing of the Contractor's plant or equipment) shall not In any way be deemed to release the Contractor from lull responsibility for complete and accurate performance of the Work In accordance with the Contract Drawings and Specifications neither shall such approval release the Contractor from any lability placed upon him by any provi- sion in the form of Contract. CL REJECTED/RESUBMIT a AMEND AND RESUBMIT MAKE CORRECTIONS NOTED N XCE ONS TAKEN __________________________ Date_ $ -