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City of Kirkwood Water Department
Specifications for the Construction of 
Water Mains and Fire Services

GENERAL

These Specifications describe requirements for the installation of water mains and fire services. If any discrepancy occurs, these Specifications shall take precedence over any Drawings.

All materials and methods of construction shall meet the requirements of the City of Kirkwood Water Department. Unless specified herein, installation shall comply with the most recent revision of American Water Works Association Standard C600.

All references to Standard Specifications shall be considered to be the most recent revision of such Standard Specifications in effect at the time of project initiation.

The verification of the location of all underground facilities, structures and utilities shall be the responsibility of the Contractor and, if damaged, shall be repaired by the Contractor at his own expense.

These Specifications are subject to revision by the Water Department without notice.

MATERIALS OF CONSTRUCTION

All materials shall be new, unused, undamaged and clean when installed.

Pipe

Pipe shall be ductile iron, cement-lined, Class 52, push-on joints meeting AWWA standard C151. Fire services shall be appropriately sized by the developer’s or contractor’s engineer. Joints shall be push-on type rubber gasket in accordance with AWWA standard C111.

Gaskets

Gaskets shall properly match bell configuration.

Polyethylene Encasement

Polyethylene encasement shall be in tube form, shall have natural (clear) color, and shall have a minimum thickness of 12 mils. Flat tube width shall correspond to the diameter of pipe being laid. Polyethylene sheets shall be used for odd shaped appurtenances. Black-colored encasement shall not be permitted.

Fittings

All fittings, which include bends, tees, crosses, plugs and caps, shall be ductile iron, slip-on connections in accordance with AWWA standard C110 or C153, and shall be cement-lined in accordance with AWWA standard C104.

Valves

Valves shall be ductile iron body, resilient wedge gate, non-rising stem type, O-ring seals, and slip-on connections (tapping valves shall be flange x mj). They shall be American Flow Control Series 2500, Kennedy Ken-Seal II, or Mueller Cat. No. A-2360. The valves shall be suitable for cold water, non-shock, bi-directional flow operation, and working pressure of 200 PSI. They shall be of such design as to maintain the full area of the pipe through the valve when open and shall be designed to take full pressure on either face. They shall be opened by turning counter-clockwise and shall have two-inch square cast iron operating nuts with an arrow cast in the nut indicating the direction of opening. Valve shall have Type 304 stainless steel bonnet bolts and nuts and type 304 stainless steel O-ring gland bolts and nuts. Valves shall have the manufacturer’s name or initials and the pressure rating cast on the body.

Valve Boxes

Valve boxes shall be provided for all valves installed. They shall have suitable bases to fit around the valve bodies without bearing on them. Barrels shall be telescopic for adjustment and shall have a minimum inside diameter of five inches. They shall be designed for the depth of trench specified. The top section shall have a flange for holding it in position. Covers shall be recessed flush with the top and marked “water” in raised letters. Valve boxes shall weigh not less than 90 lbs. 

Fire Hydrants 

Fire hydrants shall be 5-1/4” diameter valve opening, 3-way (one 4 ½” diameter steamer nozzle and two 2 ½“ diameter hose nozzles), national standard thread, six-inch diameter slip-on shoe with lugs, open counter clockwise, 1½” operating nut, and shall be American Darling B-84-B or Kennedy K81D. Bury depth of hydrants shall be such that the top of the traffic flange shall be positioned no less than two inches and no more than six inches above finished grade. The installation of hydrant extensions is not permitted.

Tapping Sleeves and Valves

Taps of four inch and larger diameter shall consist of a stainless steel tapping sleeve. The tapping sleeve shall be constructed entirely of stainless steel. Carbon steel or ductile iron flanges are not permitted. Approved sleeves include Ford FTSS, Mueller H-304, Power Seal 3490, Romac SST III, or Smith-Blair 665. The tapping valve shall comply with the requirements previously described in the valve section, with the exception of tapping valves shall be flange x mj. Tapping valves shall be American Flow Control series 2500, Kennedy Ken-Seal II, or Mueller A-2360.

Corporation Stops

Corporation stops shall be a minimum diameter of one inch and shall be sized according to the service line diameter if the service line diameter is larger than one inch. Corporation stops shall be ground key AWWA taper “CC” thread by copper flare eighth bend connection. One-inch corporation stops shall include dielectric nylon insulators, shall be Mueller N-35000 and shall include Mueller H-15063 eighth bend couplings. 1½ and 2 inch corporation stops shall be Mueller H-15020.

Service Saddles

Service saddles (used for 1 ½ and 2 inch corporation stops) shall be brass body with double flattened silicone bronze straps. Saddles shall be Ford 202B or Mueller BR2B.

Curb Stop Valves

Curb stop valves shall be flare connections, and shall not be compression type.

Service Line Couplings

Service line couplings shall connect to both new and existing copper service lines using flare connections only. Compression type end connections are allowed for connection only to existing lead or steel service lines.

MATERIAL STORAGE

All materials shall be stored in a safe and secure manner and in such a way as to prevent damage to the materials. Pipes, hydrants valves and fittings may be laid directly on the ground, but in such a way as to prevent water from accumulating inside these materials. Gaskets and polyethylene film shall be protected from direct sunlight. Gaskets shall not be allowed to come into contact with petroleum products.

If water mains or fire hydrants are stacked, the bottom tier of pipes/hydrants shall not be laid directly on the ground, but shall be held off the ground and supported by timbers. Timbers shall also be installed between each tier, preventing contact between tiers.

TRENCH EXCAVATION AND BACKFILL

The trench shall be excavated to a depth of at least six inches below the bottom of the pipe. The trench shall be at least twelve inches wider than the outside diameter of the pipe. The pipe shall be laid in the center of the trench so a minimum distance of six inches is maintained between the outside of the pipe and each trench wall.

Prior to placing the pipe, at least six inches of one-inch clean, crushed limestone bedding shall be placed and leveled in the bottom of the trench. The bedding shall be true and even, and shall provide a uniform and continuous bearing and support for the pipe, except that it will be permissible to disturb the backfill material near the center of each length of pipe to permit the withdrawal of pipe slings and other lifting equipment. All water main and appurtenances shall be inspected and approved by a Water Department representative prior to covering the new pipe. Any piping or appurtenances that are covered or otherwise hidden from view prior to receiving approval from the Water Department shall be completely uncovered in order to permit a thorough inspection.

After installation of the pipe is complete, one-inch clean crushed limestone shall be placed around each side of the pipe (six-inch minimum width on each side), and over the top of the pipe (minimum thickness of twelve inches).

Trench backfill from the top of the granular bedding to the level of existing grade adjacent to the trench shall be in accordance with the policies and procedures established by the City’s Public Works Department. Suitable native material previously excavated from trench and/or supplemental borrow material if the trench is not to be located beneath pavement of any kind. Backfill shall be placed in layers of thickness within the compacting ability of the equipment used. Compaction of the trench backfill shall be performed at the proper moisture content of the backfill material to achieve the desired results, and accomplished without inundation.

Under road pavements, sidewalks, driveways and parking lots, one-inch clean backfill shall be compacted to 95 percent of maximum dry density (see “Pipe Bedding Detail Under Pavement” on drawings). In other areas, backfill shall be compacted to the degree necessary to prevent significant future settlement.

INSTALLATION

Pipe

Pipe and fitting joints shall not be deflected more than two degrees during assembly and shall not have a deflection of more than four degrees after assembly.

Carefully examine each pipe immediately prior to installation. All visible foreign material shall be removed from the pipe immediately prior to its installation. If necessary, the Contractor shall rinse the interior surface of the pipe. Install pipelines to grades and alignment indicated. Provide proper facilities for lowering sections of pipe into trenches. Pipe shall not be rolled or dropped into the trench. Immediately prior to installing each pipe section, the previously installed section of pipe must be inspected to insure that no foreign material has entered the pipe since its installation. If any foreign material is discovered in the previously installed section of pipe, it shall be removed prior to installing the next pipe section. Polyethylene encasement shall be installed in accordance with AWWA C105. Lubricant shall be applied according to the manufacturer’s instructions and shall be in accordance with AWWA C111. Under no circumstances shall pipe be laid in water and no pipe shall be laid when trench conditions or weather are unsuitable for such work. Full responsibility for diversion of drainage and for dewatering of trenches during construction shall be borne by the Contractor. At times when pipe laying is not in progress, watertight plugs shall close the open ends of the pipe. Foreign material shall be prevented from entering the pipe during and after installation.

Mains shall not be tapped for service line connections prior to the installation, disinfection and pressure testing of the water main, unless a tap is needed for flushing and pressure testing purposes.

Water mains shall have no less than 42 inches and no more than 48 inches of cover after finished grading.  Exceptions to this rule may be made by the Water Department to provide necessary clearance from sanitary and storm sewers, and to accommodate conflicts with other utilities. Such approval must be obtained from the Water Department prior to any installation that deviates from these specifications.

If the existing grade elevation in the vicinity of the water main installation is to be altered, finished grade elevation stakes shall be set by the developer’s or contractor’s engineer prior to the installation of water main. The stakes shall be set within 10 feet of the water main trench and shall be placed at least every 50 feet along the water main route.

If, after finished grading is complete, any portion of the water main has more than 48 or less than 42 inches of cover, and this installation outside the required limitations did not receive prior approval from the Water Department, the developer shall relocate that portion of water main to the required depth at his expense.

Restrained Joint Gaskets

At every location a restrained joint gasket is installed, the Contractor shall wrap indicator tape around the joint.  The tape shall indicate the presence of a restrained joint gasket within that joint.

Polyethylene Encasement

Installation of polyethylene encasement shall be in accordance with AWWA standard C105.

Polyethylene shall also encase socket clamps, threaded rod, washers and nuts.  Encasement shall be secured with duct tape.

All pipes, valves, fittings, tie rods, clamps, and appurtenances shall be protected with clear polyethylene encasement. The encasement shall prevent contact between the pipe and the surrounding backfill and bedding material.

Bends

All bends shall be installed with thrust blocks adequately sized for the degree of bend, diameter of bend, and anticipated system pressure. In lieu of thrust blocks, the contractor may use joint restraint gaskets to restrain the bend to the pipe. If the contractor chooses to use restrained joint gaskets in lieu of thrust blocks, additional joint restraint gaskets will be required in each direction from the bend. The contractor may also choose to pour a “dead man” concrete thrust block around the first pipe joint in both directions from the bend. These two joints within the concrete “dead man” thrust blocks shall also contain joint restraint gaskets.

Fittings

Plugs shall be restrained in bells of pipe and fittings by setscrews and concrete thrust blocks. Caps shall be restrained to pipe with two sets of socket clamps and threaded rod, and by concrete thrust blocks.

Valves

Valves shall be installed in a horizontal position with the operating nut vertical.

Valve Boxes

A valve box shall be installed above each valve. Valve boxes shall be installed such that the top of the box is no more than ¼ inch below street pavement, flush with sidewalk pavement, or when in lawns, flush with the dirt surface.  Valve boxes shall never pose a trip hazard or a potential threat of damage to lawn mowers.

Tapping Sleeves and Valves

Immediately prior to installation, the following surfaces shall be sprayed with household bleach until thoroughly wet:

1)      The interior of the tapping sleeve branch

2)      The interior of the tapping valve, including both sides of the gate.

3)      The pilot drill bit and the shell cutter of the tap machine

Corporation Stops

Corporation stops shall be installed only after the water main has been installed and has been placed into service. They shall be installed on the water main at 10 o’clock or two o’clock positions on the water main diameter. One-inch diameter corporation stops shall be direct tapped to the water main. 1 ½ and 2-inch diameter corporation stops shall be attached to the water main with service saddles. Dielectric nylon service insulators shall be installed between two flare copper adapters.

Connections between the service line and the corporation stop shall be supported with blocking, the uppermost layer of blocking being of wood.

Curb Boxes

Curb boxes shall be installed vertically and shall be perfectly centered over the curb stop valve.

Curb boxes shall be installed such that the top of the box is flush with the dirt surface. Curb boxes shall never pose a trip hazard or a potential threat of damage to lawn mowers.

Service Line Transfers

When the Contractor connects any existing water service to the new tap, he must coordinate with the Water Department personnel to enable Department personnel to remove the water meter from the service line before the new corporation stop is turned on. Once the meter is removed, the Contractor shall turn the corporation stop fully on. Department personnel will flush the service line into the meter box and replace the meter. If the Contractor fails to properly coordinate this process with Department personnel, and failure to do so causes plugging of the resident’s plumbing fixtures, the contractor shall be responsible for cleaning and/or replacing the resident’s fixtures.

Pipe Clamps and Rods

In-line valves, fittings, bends or tees need not be anchored to the “run” pipe with threaded rod. Threaded rod, rod nuts and washers, if used, shall be thoroughly coated with a bituminous coal tar spray after installation.

Threaded rods and socket clamps, when used, shall be installed prior to placing concrete thrust blocks.

FIRE SERVICE VAULTS

Vaults shall be adequately sized to contain: 1) pipe tee that splits the fire and domestic services;  2) double or single detector check valve; including OS&Y valves on both ends; 3) detector meter, valves, and double or single check valve on detector meter bypass; 4) collapsible fitting; 5) domestic meter (if 1 ½” or larger), valves at both ends, bypass line; 6) any and all appurtenances required by the Fire Department.

Domestic water meters 1” diameter or smaller shall not be installed within the main fire service vault, but shall be installed in a standard residential meter box immediately next to the main fire service vault.

Backflow Preventors/Detector Meters

Backflow preventors for fire services may be installed in the fire service vault. Backflow preventors installed in the fire service vault shall be double detector check valves. If the backflow preventor is installed inside the building, a single detector check valve shall be installed in the fire service vault. Single detector check valves shall not be installed in pyramid vaults, but shall be installed in vaults large enough to contain the detector check valve, both OS&Y valves, and collapsible fitting. Detector meters on both double and single detector check valves shall be purchased from the City and installed by the contractor.

Both double and single detector check valves installed in fire service vaults shall have installed OS&Y valves at both ends. A collapsible fitting, assembled using two flange X plain end pipes, and a mechanical joint coupling connecting the two plain ends, with approx. a 1” gap between the plain ends, shall be installed by the contractor.

SEPARATION OF WATER MAINS, SANITARY AND STORM SEWERS

Water mains installed parallel to any sanitary sewer pipe line shall be installed with no less than 10 feet of horizontal separation between the outside of the water main and the outside of the sewer. Where 10 feet of separation is not possible, the entire water main located 10 feet or less from the sanitary sewer shall be encased in concrete.

Water mains crossing sanitary sewer pipelines shall be installed to provide no less than 18 inches of vertical clearance between the two pipelines.  At crossings in which water main will already have at least 18 inches of clearance from the sanitary sewer, a full length of water main shall be installed so both joints will be as far from the sewer as possible.

No water main shall be located closer than 10 feet to any part of a sanitary sewer manhole.  Where 10 feet of separation is not possible, the entire water main located 10 feet or less from the sanitary manhole shall be encased in concrete.

Water mains crossing storm sewers shall be installed to provide a minimum vertical clear distance of six inches between the outside of the water main and the outside of the storm sewer.

If necessary, the Contractor shall install four 45° bends to achieve the minimum clearance between the water main and sanitary or storm sewers.

FIRE HYDRANT INSTALLATION

Hydrants shall stand plumb with pumper nozzles facing the curb. They shall be installed so the top of the traffic flange is no less than two inches and no more than six inches above finished grade. The installation of hydrant extensions is not permitted. Hydrant supply branches shall be controlled by an independent resilient seat gate valve.

Valves shall be slip-on and shall be restrained to tees using restrained joint gaskets or threaded rods, to allow shut-off when the hydrant is to be removed.  Hydrants shall be restrained to valves using restrained joint gaskets or threaded rods. Regardless of which restraint system is used, thrust blocks shall always be poured between the back of the hydrant bowl and undisturbed earth.

Hydrants shall be installed between the street curb and the sidewalk, 24-32 inches from back of street curb. Once final landscaping has been completed, the Contractor shall remove all nozzle cap chains, thoroughly clean and remove all rust from the hydrant, and paint the hydrant with a gloss finish oil-based alkyd coating. The color shall be safety yellow.

THRUST BLOCKS

Thrust blocks shall be installed in accordance with the details and table shown on the Miscellaneous Details Sheet.

Concrete thrust blocks shall be installed at all fittings, bends, hydrants and changes in alignment of the water main to take the thrust of the water pressure. Thrust blocks shall have a compressive strength of not less than 2000 psi after 28 days.

Blocks shall distribute the thrust forces to the soil structure in such a manner that joint separation will not occur. The blocks shall be so located as to contain the resultant thrust force in such a way that the pipe and fitting joints will be accessible for repair. Final approval of thrust block sizing and installation shall be at the discretion of the Water Department.

The Contractor may use restrained joint gaskets as an alternative to thrust blocks (with the exception of fire hydrants) upon prior approval by the Kirkwood Water Department.  The number and location of restrained joints upstream and downstream of the point of thrust must be selected by the Contractor according to the water pressure and soil conditions, and shall be subject to approval by the Water Department.

INSPECTIONS

All piping and appurtenance installation shall be inspected and approved by Water Department personnel prior to backfill. Any portion of work that is backfilled prior to inspection shall be uncovered at the Contractor’s expense to enable Water Department personnel to thoroughly and adequately inspect all work. The Contractor shall provide sufficient access and reasonable aid to the inspector to allow for thorough inspections of the work.

DISINFECTION

All piping shall be disinfected in accordance with AWWA standard C651 prior to being placed into service. Disinfection shall be by the granular method. Calcium hypochlorite granules (HTH) shall be placed inside the upstream end of the first section of pipe, and every 500 feet thereafter. In addition, granules shall be placed inside the upstream end of each branch main, and every 500 feet thereafter. The quantity of granules placed shall correspond to Table 1 of the AWWA Specification. Eight-inch diameter main receives a minimum of seven ounces of granules at each application point.

Following installation, the main shall be filled and flushed. The filling and flushing procedures shall be performed by Water Department personnel only. The contractor is not allowed to fill or flush the main.  If a fire hydrant does not exist on the new main, the Contractor shall, at his expense, install a one-inch minimum diameter corporation stop in the top of the main at the highest elevation for flushing and sampling purposes. Following acceptable bacteria test results, the contractor shall remove the tap and replace it with a bronze plug. Water Department personnel shall collect all bacteria samples and shall conduct all bacteria analyses. If the contractor does not want bacteria samples collected from a fire hydrant, he may, at his expense, install a tap for sampling purposes. Following acceptable bacteria test results, the contractor shall remove the tap and replace it with a bronze plug. If bacteria analyses fail to produce acceptable results, Water Department personnel will repeat the flushing, sampling and bacterial analyses procedure a second and, if necessary, a third time.

If, after the third attempt, water quality does not meet requirements, the Contractor, at his expense, shall fill the entire length of water main with a solution of water containing no less than 50 parts per million available chlorine. After 24 hours contact time, the Water Department will perform another flushing, sampling and bacterial analyses procedure. This process will be repeated until results are acceptable.

HYDROSTATIC TESTING

Unless specified herein, all underground piping shall be tested hydrostatically by the contractor in accordance with AWWA standard C600. Test pressure shall not be less than 1.5 times the working pressure at the point of testing, or not less than 100 PSI, whichever is greater. The duration of the test shall be a minimum of two hours. Test pressure shall not vary by more than +/- 5 PSI for the test duration.  The Contractor may use a fire hydrant on the new main to conduct the pressure test, or may install a corporation stop for a test connection.

Leakage is defined as that quantity of makeup water that must be supplied to maintain, within 5 psi, the specified test pressure for the entire two-hour test duration. Pressure drops shall not be used to measure leakage. If the new main does not pass the pressure test and a leak cannot be found, it will be the contractor’s responsibility to disconnect the new main from the existing main, cap the new main at those connections, and perform another pressure test to eliminate the possibility of leakage through the valves at the connections to the existing mains.

Maximum allowable leakage shall be in conformance with AWWA standard C600, Table 6A. All visible leaks are to be repaired, regardless of the amount of leakage. Testing and replacement of any section of pipe, valve or fitting shall be performed by the Contractor at his expense.

When a hydrant is not being installed along the new water main, the Contractor shall install a one-inch diameter corporation stop at the highest elevation on the new main and on top of the pipe for flushing, sampling, and pressure testing.  Once the pressure test is completed and approved, the contractor shall remove the corporation stop and install a brass plug.

Hydrostatic testing shall be observed by and approved by a Water Department representative.

FINAL CONNECTIONS

If the Contractor connects the new main to an existing main after the new main has successfully passed the bacteriological testing, the interior of all new materials used to make the final connection shall be thoroughly sprayed with household bleach immediately prior to their installation. If the Contractor connects the new main to an existing main after the new main has successfully passed the pressure test, water to all portions of the new connection(s) must be turned on and the new connection(s) pressurized. These connections shall be left under full system pressure for a minimum of twenty-four (24) hours, at which time they will be inspected for leaks by Water Department personnel.

SHUTDOWNS OF EXISTING MAINS

When water service to existing customers must be interrupted to sections of mains to enable the contractor to disconnect and abandon water mains, or for any other scheduled reason, the contractor shall provide the Water Department with a 24-hour minimum notice. Water Department personnel will notify those customers to be affected by door hanger notices on the day prior to the scheduled shutdown. Scheduled shutdowns shall not begin prior to 9:00am or extend beyond 3:00pm. If the contractor encounters unforeseen difficulties, he must continue working until service has been restored. When transferring individual single-family residential services to the new main, the contractor shall be responsible for delivering notice to the occupant. Twenty-four hour notice and door hangers are not required for individual single-family residential service transfers.

SITE SAFETY AND PROPERTY PROTECTION

The Contractor shall, at all times, conduct his operations in such a manner and employ all reasonable means to prevent damage to public and private property. Any damage to public or private property as a result of the contractor’s failure to comply with any portion of these specifications or federal, state or local regulations shall be repaired at the contractor’s expense. 

The contractor shall keep all utilities marked while excavating in their vicinity.

The Contractor shall, at all times, comply with the City’s Public Works Department’s Excavation, Restoration and Land Disturbance Requirements. 

Trees, shrubs, miscellaneous plantings, planter areas, ornamental structures, retaining walls and all other structures shall be protected from damage during construction, and shall be supported or temporarily relocated if necessary at the Contractor’s expense. Items shown in the drawings or plans to be removed and reinstalled shall be protected by the Contractor while in storage.

Support and protection of all structures, both above ground and below, and within the immediate vicinity of the work, shall be the Contractor’s responsibility at his expense.

TRAFFIC CONTROL

Traffic control shall comply with all applicable Federal, State and Local regulations. Adequate barricades, warning signs and lights shall be installed and maintained on a continuous basis by the Contractor. These safety devices shall be adequate to advise, warn and protect the public from any hazards arising from or otherwise associated with the Contractor’s work. The Contractor shall, at all times, comply with the City’s Public Works Department’s Excavation, Restoration and Land Disturbance Requirements. 

SITE CLEANLINESS

The contractor shall maintain the construction site in a neat and orderly appearance. Streets, sidewalks, parking lots and curbs shall be shoveled and swept clean of mud, dirt and debris on a daily basis and washed down as necessary. All trash and waste materials shall be removed from the site on a daily basis. Any excavated material that is not to be reused shall be removed from the site immediately. Any excavated material that is to be reused may be stored on site, but shall not be stored in the street or on a sidewalk. Stored excavated material shall be covered with plastic at all times to prevent runoff from precipitation. Site cleanliness and the storage of materials shall, at all times, comply with the City’s Public Works Department’s Excavation, Restoration and Land Disturbance Requirements.

PROPERTY RESTORATION

The contractor shall restore all disturbed areas as nearly as practicable to their original condition. 

Disturbed grass areas include not only those areas disturbed for excavation and installation of pipe and appurtenances, but also those areas disturbed by storage of materials, and operation and storage of equipment.

Any sod installed after June 15 that does not indicate substantial growth in the fall shall be replaced by the Contractor at his expense.

All street, driveway and sidewalk pavement repair and replacement, and lawn repair shall, at all times, comply with the City’s Public Works Department’s Excavation, Restoration and Land Disturbance Requirements.

WARRANTY

The contractor shall guarantee materials and workmanship for a period of not less than one year from the time the main is placed into service. Any leaks that develop within the first year shall be repaired by the developer/contractor. The contractor is responsible for deterioration or settlement of restored areas for a period of one year after completion of all restorations.

Specifications last revised August 2003