Section 15009 STEEL PIPE – FABRICATED SPECIALS

Section 15009

STEEL PIPE – FABRICATED SPECIALS

PART 1 - GENERAL

1.1 THE REQUIREMENT

A. The CONTRACTOR shall furnish all tools, equipment, materials, and supplies and shall perform all labor required to complete the Work as indicated on the Drawings and specified herein.

B. This section covers fabricating, installing, and testing all bends, reducers, wyes, tees, crosses, outlets, manifolds, and other steel plate specials, complete, in place, in accordance with the requirements of the Contract Documents.

1.2 RELATED WORK SPECIFIED ELSEWHERE

A. The requirements of the following sections and divisions apply to the Work of this section. Other sections and divisions of the Specifications, not referenced below, shall also apply to the extent required for proper performance of this Work.

1. Section 02666, Water Pipeline Testing and Disinfection

2. Section 05500, Miscellaneous Metalwork

3. Section 09800, Protective Coating

4. Section 15000, Piping, General

5. Section 15008, Steel Pipe – Mortar-Lined and Mortar-Coated

6. Section 11250, Sludge Cake Pumping System

1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS

A. All Work specified herein shall conform to or exceed the applicable requirements of the referenced portions of the following publications to the extent that the provisions thereof are not in conflict with other provisions of these Specifications.

B. Comply with the applicable editions of the following codes, regulations and standards.

1. Industry Standards:

AWWA C200 Steel Water Pipe 6 inches (150 millimeter) and

Larger

AWWA C208 Dimensions for Fabricated Steel Water Pipe

Fittings

AWWA M11 Steel Water Pipe - A Guide for Design and

Installation

ASTM A 234 Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM E 165 Standard Practice for Liquid Penetrant

Examination for General Industry

C. Comply with the applicable reference Specifications as directed in the General

Requirements and Additional General Requirements.

1.4 CONTRACTOR SUBMITTALS

A. Submittals shall be made in accordance with the General Requirements, Additional

General Requirements and as specified herein.

B. Shop Drawings: The CONTRACTOR shall submit shop drawings and laying diagrams of all pipe, joints, bends, reducers, wyes, tees, crosses, outlets, manifolds, and other steel plate specials.

C. Design calculations shall be submitted to the ENGINEER for review prior to manufacture of pipe specials.

D. Certifications: A certified affidavit of compliance shall be furnished for all steel plate specials and other products or materials furnished under this section of the Specifications.

1.5 QUALITY ASSURANCE A. General

1. Shop Testing of Steel Plate Specials: Upon completion of the welding, but prior to lining and coating, each steel plate special shall be bulkheaded and tested under a hydrostatic pressure of 1.5 times the design pressure; provided that if straight pipe used in fabricating the specials has been previously tested and meets the requirements of the applicable piping section, no further hydrostatic testing will be required; or provided that all other welded seams are tested by the liquid penetrant inspection procedure conforming to ASTM E 165 under Method "B" and "Leak Testing" or where applicable by the soap and compressed air method at an air pressure of 25 pounds per inch. Any pin holes or porous welds that may be revealed by the test shall be chipped out and rewelded and the pipe or fitting retested.

2. No outside mortar shall be applied over a seam prior to testing; however, mortar lining may be applied over a seam prior to hydrostatic testing, but under such conditions said pressure test shall be held on the pipe or fitting for a period of not less than 30 minutes.

3. Field Testing: Field testing shall conform to the requirements of Section 15000, Piping, General.

PART 2 - PRODUCTS

2.1 GENERAL

A. Specials are defined as fittings, closure pieces, bends, reducers, wyes, tees, crosses, outlets, manifolds, and other steel plate specials wherever located, and all piping aboveground or in structures.

2.2 FABRICATION AND MATERIALS

A. General: Reinforcement for wyes, tees, outlets, and nozzles shall be designed in accordance with AWWA M11. Reinforcement shall be designed for the design pressure specified or shown and shall be in accordance with the details shown. Specials and fittings shall be equal in pressure design strength and shall have the same lining and coating as the adjoining pipe. Unless otherwise shown, the minimum radius of elbows shall be 2.5 times the pipe diameter and the maximum miter angle on each section of the elbow shall not exceed 11.25 degrees.

B. Specials and fittings that cannot be mechanically lined and coated shall be lined and coated by hand application, using the same materials as are used for the pipe and in accordance with Section 15008 and the applicable AWWA or ASTM Standards. Coating and lining applied in this manner shall provide protection equal to that specified for the pipe. Fittings may be fabricated from pipe that has been mechanically lined and/or coated. Areas of lining and coating that have been damaged by such fabrication shall be repaired by hand-applications in accordance with applicable AWWA or ASTM Standards.

C. Access maintenance holes with covers shall be as detailed. All threaded outlets shall be forged steel suitable for 3000 pounds per inch service.

D. Moderate deflections and long radius curves may be made by means of beveled joint rings, by pulling standard joints, by using short lengths or pipe, or a combination of these methods; provided that pulled joints shall not be used in combination with bevels. The maximum total allowable angle for beveled joints shall be 5 degrees per pipe joint. Bevels shall be provided on the bell ends. Mitering of the spigot ends will not be permitted. The maximum allowable angle for pulled joints shall be in accordance with the manufacturer's recommendations or the angle that results from a 3/4-inch pull out from normal joint closure, whichever is less. All horizontal deflections or fabricated angles shall fall on the alignment. All vertical deflections shall fall on the alignment and at locations adjacent to underground obstructions, points of minimum earth cover, and pipeline outlets and structures. The pipe angle points shall match the angle points shown.

E. Outlets, Tees, Wyes, and Crosses: Outlets 12 inches and smaller may be fabricated from Schedule 30 or heavier steel pipe in the standard outside diameters, i.e., 12-

3/4 inches, 10-3/4 inches, 8-5/8 inches, 6-5/8 inches, and 4-1/2 inches.

F. The design of outlet reinforcement shall be in accordance with the procedures given in Chapter 13 of AWWA M11, except that the design pressure, P, used in the M11 procedure shall equal the greater of 1.25 Pw or 0.9375 Pt. Unless otherwise shown, outlets 2 inches in diameter and smaller need not be reinforced.

G. In lieu of saddle or wrapper reinforcement as provided by the design procedure in AWWA M11, pipe or specials with outlets may be fabricated in their entirety of steel plate having a thickness equal to the sum of the pipe wall plus the required reinforcement.

H. Where required by AWWA M11 design procedure crotch plate reinforcement shall be furnished.

I. Steel Welding Fittings: Steel welding fittings shall conform to ASTM A 234.

J. Ends for Mechanical-Type Couplings: Except as otherwise provided herein, where mechanical-type couplings are indicated, the ends of pipe shall be banded with Type C collared ends using double fillet welds. Where pipe 12 inches and smaller is furnished in standard schedule thicknesses, and where the wall thickness equals or exceeds the coupling manufacturer's minimum wall thickness, the pipe ends may be grooved.

K. Lining: All requirements pertaining to thickness, application and curing of lining specified for straight pipe shall apply to specials, with the following proviso. If the special cannot be lined centrifugally, it shall be lined by hand. In such case, the lining shall be reinforced with 2-inch x 4-inch x No. 12 welded-wire fabric positioned approximately in the center of the lining. The wires spaced 2 inches on centers shall extend circumferentially around the pipe with the fabric securely fastened to the pipe. Splices shall be lapped 4 inches and the free ends tied or looped to assure continuity.

L. Coating: All requirements pertaining to thickness, application and curing of coating specified for straight pipe shall apply to specials. Unless otherwise shown, the mortar coating on the buried portion of a pipe section passing through a structure wall shall extend to the center of the wall, or to the wall flanges, if one is indicated. Pipe above ground or in structures shall be field-painted as specified in Section 09800, Protective Coating.

M. Marking: A mark indicating the true vertical axis of the special shall be placed on the top and bottom of the special.

PART 3 - EXECUTION

3.1 GENERAL

A. Unless otherwise provided, the CONTRACTOR shall furnish and install all fittings, closure pieces, bends, reducers, wyes, tees, crosses, outlets, manifolds, and other steel plate specials, bolts, nuts, gaskets, jointing materials, and all other appurtenances as shown and as required to provide a complete and workable installation. Where pipe support details are shown, the supports shall conform thereto and shall be placed as indicated; provided, that the support for all exposed piping shall be complete and adequate regardless of whether or not supporting devices are specifically shown. Where shown, concrete thrusts blocks and welded joints shall be provided.

B. At all times when the work of installing pipe is not in progress, all openings into the pipe and the ends of the pipe in trenches or structures shall be kept tightly closed to prevent entrance of animals and foreign materials.

C. The CONTRACTOR shall take all necessary precautions to prevent the pipe from floating due to water entering the trench from any source, shall assume full responsibility for any damage due to this cause and shall at its own expense restore and replace the pipe to its specified condition and grade if it is displaced due to floating.

D. The CONTRACTOR shall maintain the inside of the pipe free from foreign materials and in a clean and sanitary condition until its acceptance by the ENGINEER.

3.2 LAYING

A. Trenches shall be in a reasonable dry condition when the pipe special is laid. Necessary facilities including slings shall be provided for lowering and properly placing the pipe sections in the trench without damage. The pipe and specials shall be laid to the line and grade shown, and they shall be closely jointed to form a smooth flowline.

B. Immediately before placing each section of pipe in final position for jointing, the bedding for the pipe shall be checked for firmness and uniformity of surface.