VALVES, FIRE HYDRANTS AND APPURTENANCES

PART 1 - GENERAL

1.01  SECTION INCLUDES

A. Butterfly valves

B. Gate valves

C. Tapping valve assemblies

D. Fire hydrant assemblies

E. Flushing Devices (blowoffs)

F. Valve boxes

G. Incidental items

1.02  DESCRIPTION OF WORK

A. Install valves, fire hydrants, and appurtenances for water mains.

B. Reference is made to the Iowa Department of Transportation Standard Specifications for Highway and Bridge Construction, Series 2001, and all current General Supplemental Specifications and Materials Instructional Memorandum by the term "Iowa DOT Specifications" and/or "Iowa DOT I.M."

1.03  SUBMITTALS

A. Submit under provisions of Division 1.

B. Manufacturer's instructions for installation for all valves, hydrants and assemblies.

C. Construction sequencing.

D. Catalog cuts, samples, manufacturer's data and listing of applicable standards for special, unique or proposed substitute materials if requested by Jurisdictional Engineer.

E. Upon requests the Contractor will provide Material Certifications to the Jurisdictional Engineer.

Follow the General Provisions (Requirements) and Covenants.

1.04  SUBSTITUTIONS

A. Use only materials conforming to these specifications unless permitted otherwise by Jurisdictional Engineer.

B. Obtain written approval of Jurisdictional Engineer for all substitutions prior to use.

Follow the General Provisions (Requirements) and Covenants.

1.05 DELIVERY, STORAGE, AND HANDLING

A. Deliver only materials that fully conform to these specifications, or for which submittals have been provided to Jurisdictional Engineer and approved for use.

B. Store materials in a protected environment, on pallets or lagging.

Follow the General Provisions (Requirements) and Covenants, as well as the following:

C. Valves Remove valves, fire hydrants, and appurtenances contaminated with mud and surface water shall be removed from the site; and do not used use in construction unless thoroughly cleaned, inspected, and approved by Owner the owner.

D. Handle all materials so as to avoid damage. Remove from the site and replace any damaged materials.

1.06 SCHEDULING AND CONFLICTS

A. Construction Sequence:

1. Attend a preconstruction meeting if required by Jurisdictional Engineer.

2. Submit plan for construction sequence prior to commencing construction unless specifically not required by Jurisdictional Engineer.

B. Conflict Avoidance:

 1. Expose possible conflicts In advance of construction, such as utility lines and drainage structures.  Verify elevations of each and verify clearances for proposed construction.

2. Complete elements of the work which can affect line and grade in advance of other open cut construction unless noted on plans.

3. Notify Jurisdictional Engineer of any conflicts discovered or any changes needed to accommodate unknown or changed conditions.

Follow the General Provisions (Requirements) and Covenants.

1.07  SPECIAL REQUIREMENTS

A. Stop Work:  Stop work and notify Jurisdictional Engineer immediately if contaminated soils, historical artifacts or other environmental or historic items are encountered.

B. Conform to local, state and federal requirements.

None.

1.08 MEASUREMENT FOR AND PAYMENT

All measurements for payments will be made by the Jurisdictional Engineer or authorized representative.

A. Butterfly Valve (Butterfly or Gate):

2.1. Count each butterfly valve of each size installed. Measurement: Each type and size of valve installed will be counted.

3.2. Payment: Payment shall will be at the unit bid price for each size and type and size of valve properly installed.

1.3. Butterfly valve item Includes: Unit price includes, but is not limited to, all components attached to the valve or required for its  complete installation, including but not limited to underground or above ground operator, square valve operating nut, valve box and cover, valve box extension, and valve stem extension shaft sufficient to position the valve operating nut within two feet and below the ground surface, and hand wheels and incidental items.

B. Gate Valve:

1. Gate valve includes all components attached to the valve or required for its complete installation, including but not limited to underground or above ground operator, square valve operating nut, valve box, valve box extension, extension shaft sufficient to position the valve operating nut within two feet and below the ground surface, hand wheels, and Incidental items.

 2. Count each gate valve of each size installed.

 3. Payment shall be at the unit bid price for each size and type of valve installed.

 4. See subparagraph 1.08.D for payment for valves on fire hydrant leads.

C.B. Tapping Valve Assembly:

2.1. Count each tapping valve assembly of each size installed Measurement: Each size of tapping valve assembly will be counted..

2. Payment: Payment will be at the unit price for each tapping valve assembly properly installed.

1.3. Includes: Unit price includes, but is not limited to, tapping sleeve, tapping valve, the tap, valve box and cover, valve box extension, and valve stem extension and all other components needed to complete the installation, and for successfully completing of the tap.

DC. Fire Hydrant Assembly:

2.1. Count each Measurement: Each fire hydrant assembly installed will be counted.

2. Payment: Payment will be at the unit price for each fire hydrant assembly properly installed.

1.3. Includes: Fire hydrant Unit price includes, but is not limited to, the fire hydrant, with barrel extensions sufficient to achieve proper hydrant bury depth of anchor pipe and height of fire hydrant above finished grade, length of the unit and components to connect the fire hydrant to the water main, including anchor pipe, fittings, thrust blocks, pea gravel or porous backfill material, and fire hydrant gate valve, except tapping valve assembly if used.

3. Components to connect the fire hydrant to the water main, including pipe, fittings and auxiliary valve, except tapping valve assembly if used, shall be considered to be integral parts of the fire hydrant assembly, and no separate or additional payment shall be made therefor.

E.D. Flushing Device (Blowoff):

1. Each blowoff assembly includes the valve, fittings, and all pipe segments. Pipe used in the blowoff assembly shall not be paid for separately under any other item.

2.1. Measure each blowoff assembly of each size installed by numerical count. Measurement: Each size of flushing device will be counted.

2. Payment: Payment will be at the unit price for each flushing device properly installed.

F. Valve Box:

1. Each valve box shall include the lid and any extensions required extend from the valve to the ground surface.

 2. Valve box or extensions shall not be measured separately for payment unless identified separately in the Bid Schedule as a payment item.  If so identified, measure each valve box, with extensions, if any, as a unit.

G. Incidental Items:

1. Items required for proper completion of the work or required by applicable codes, and whether or not the items are shown in the Plans, but which are not shown in the Bid Schedule, shall be considered incidental to the contract.

2. No separate payment shall be made for incidental items.

PART 2 - PRODUCTS

2.01  VALVES

A. General:

1. Same size as pipeline in which it is installed, unless noted otherwise on the drawings plans.

2. Manufacturer's name or and initial and working pressure rating cast on valve body.

3. Open when turned counterclockwise for most jurisdictions. If the contractor is not sure of the direction of opening of the valve, the contractor is to contact the Jurisdiction. Direction of Opening: The opening direction is counterclockwise as viewed from the top, unless otherwise specified in the contract documents or as directed by the Jurisdiction.

4. Factory tested to twice the rated working pressure.

5. Buried service:  Mechanical joints, unless noted otherwise on Plans.

6. Service within structure:

a. Flanged, per ANSI/AWWA C110/A21.10.
b. Flanges, drilled to conform to ASME/ANSI B16.1 class 125, unless noted otherwise on drawings.

7. All valve operators to be supplied by valve supplier.

8. Bolts for joints:  Refer to Section 5010.

4. Joints:

a. For buried installations, use mechanical joints per AWWA C111. Comply with Section 5010 for joint nuts and bolts.
b. For installation within structures, flanged with dimensions and drillings per AWWA C110 or ANSI B16.1 class 125.

B. Gate Valves:

1. Comply with AWWA C509 (gray iron or ductile iron) or AWWA C515 (ductile iron) and NSF 61.

2. Stem Seals: Double O-rings permanently lubricated between seals. Lubricant certified for use in potable water.

3. External Bolts and Hex Nuts: Stainless steel per ASTM A 240, type 304.

B.C. Butterfly Valves, Buried Service:

1. Type: Rubber seat.

2. Pressure rating: 150 psi working pressure.

3. Bubble-tight at rated pressures with flow in either direction.

4. Comply with:  ANSI/AWWA C504 class 150B.

5. Body:

a. Gray iron per ASTM A 126 class B.
b. Two trunnions for shaft bearings.

6. Ends:

a. Flanged, with flange adapters, except as otherwise shown in the Plans.
b. Flange adapter:  Refer to Section 5010.

1. Comply with AWWA C504 class 150B (gray iron or ductile iron) and NSF 61.

7.2. Disc: Ductile iron or gray iron with plasma applied nickel-chromium edge or stainless steel edge per ASTM A 240, Type 316, and mechanically fixed stainless steel pins.

a. Material:  Ductile iron ASTM A 536 or Gray iron ASTM A 126 class B, with plasma applied nickel-chromium edge or ASTM A 240, Type 316 stainless steel edge.
b. Connection to shaft: Mechanically fixed stainless steel pins.

8.3. Shaft Stem: Stainless steel per ASTM A 240, Type 304, turned, ground, and polished.

a. Material: Stainless steel, ASTM A 240, Type 304.
b. Turned, ground and polished.

9.4. Seat: Synthetic rubber compound bonded or mechanically retained to the body.

a. Material:  Synthetic rubber compound.
b. Simultaneously molded in, vulcanized and bonded to body or mechanically retained.

10. Bearings:

a. Corrosion resistant non-metallic and self-lubricating, sleeve type.
b. Bearing load:  No greater than 1/5 the compressive strength of the bearing or shaft material.

11. Packing:  Self adjusting chevron type.

12. Operator:

a. Type: Buried service.
b. Three bolt, minimum, mounting to valve.
c. Hold valve in any intermediate position between fully open and fully closed without creeping or fluttering.
d. Equipped with mechanical stop-limiting devices to prevent over-travel of the disc in the open and closed positions.
e. Fully enclosed, gasketed and grease packed.
f.  Designed to operate the valve under full rated working pressure with a maximum of 80 foot-pounds applied force.
g. Withstand an input of 450 foot-pounds at extreme operator position without damage.

13. Finish:  In accordance with ANSI/AWWA C504.

14.5. Exposed External Bolts and Hex Nuts:  Stainless steel per ASTM A 240, Type 304.

C. Gate Valves, Buried Service:

1. Type: Non-rising stem, resilient seat.

2. Pressure rating: 200-psi working pressure, minimum.

3. Comply with:  ANSI/AWWA C509.

4. Body, Bonnet and Discs: Gray iron per ASTM A 126 class B.

5. Ends:  Mechanical connection, except as otherwise shown on the plans.

6. Seat:  Field replaceable with stainless steel fasteners.

7. Shaft seals: Double O-rings permanently lubricated between seals.  Lubricant certified for use in potable water.

8. Exposed bolts and hex nuts: ASTM A 240, Type 304 stainless steel.

9. Operator: 2-inch square nut.

10. Interior and exterior valve coating shall be minimum 10-mil thick fusion bonded epoxy per AWWA C550.

11. Valve design shall not allow metal-to-metal contact between gate and body.

D. Tapping Valve Assemblies:

1. Valve:  Tapping valve conforming to ANSI/AWWA C509.

1. Tapping Valve: Gate valve complying with AWWA C509 or AWWA C515.

2. Sleeve:

a. Minimum 14 gauge.
b. Stainless steel, per ASTM A 240, Type 304.
c. Working pressure 200 150 psi.
d. Must fully surround pipe.
e. Refer to table for minimum sleeve length


e. Flanged with dimensions and drillings per AWWA C110 or ANSI B16.1 class 125.

3. Minimum Sleeve Length:

Outlet Flange Size Minimum Sleeve Length
4" 15"
6" 15"
8" 20"
10" 25"
12" 25"
Over 12" As approved by the Engineer

3.4. Gasket:

a. To completely surround pipe.
b. Minimum thickness 0.125 inch.
c. Material: Use nitrile rubber.

4.5. Outlet Flange:

a. Stainless steel, ASTM A 240, Type 304.
b. ANSI B16.1, 125 pound pattern.

5.6. Hex Nuts and Bolts: Stainless steel, ASTM A 240, Type 304.

6. Minimum sleeve length:

Outlet Flange Size
(Inches)

Minimum Sleeve Length
(Inches)

4

15

6

15

8

21

10

27

12

30

Sizes over 12 inch

Consult Jurisdictional Engineer

7. Consult Jurisdictional Engineer for applicability. Use tapping valve assemblies only where approved and authorized or shown on the plans.

2.02 FIRE HYDRANT ASSEMBLY

A. Material: Conform to ANSI/AWWA C502, as modified herein Comply with AWWA C502.

B. Manufacturers: As allowed by the Jurisdiction or specified in the contract documents.

C. Features:

1. Break-away Breakaway Stem Coupling and Breakaway Flange.

2. Inlet Nominal Size: 6 Inch Diameter.

3. Inlet Connection Type: Mechanical Joint.

4. Hose Nozzles: tTwo, Each 2 1/2 Inches In diameter.

5. Direction of Opening: Counterclockwise, unless otherwise specified.

5. For the following items, as allowed by the Jurisdiction or specified in the contract documents:

a. Operating nut: Pentagonal, size of 1-3/16 inches or 1-1/2 inches.
b. Pumper nozzle: 4 inches or 4-12 inches in diameter.
c. Nozzle Threads: National Standard or specific local requirements.
d. Nominal bury length: Same depth as water main.
e. Main valve nominal opening size: 4-1/2 inches or 5-1/4 inches in diameter.
f. Direction of opening: Counter clockwise or clockwise.

6. The following items will be specified by the Jurisdiction or contract documents:

a. Operating nut.
b. Pumper nozzle
c. Nozzle threads
d. Main valve nominal opening size.

D. Substitutions: None, unless approved in writing by Jurisdictional Engineer.

E.D. Painting:

1. Shop coating; per ANSI/AWWA C502.

2. Field coating above grade; Exterior coating, Above grade exterior coating type and color selection will be selected by the Jurisdictional Engineer.

F. Provide auxiliary gate valve with valve box conforming to Section 5020, 2.01, C. Refer to Detailed Drawings.

G.E. Exposed External Bolts And Hex Nuts:  Stainless steel, ASTM A 193, Grade B 8.

F. Gate Valve: Comply with Section 5020, 2.01.

G. Pipe and Fittings: Comply with Section 5010.

2.03  APPURTENANCES

A. Flushing Device (Blowoff): As specified.

1. Construct according to Detailed Drawings for Temporary or Permanent unit.  Refer to Plans for applicable type at each location.

2. Nominal size: Two pipe diameters less than the water main to which it is attached.

3. Locations:  Where shown on the Plans.

4. Components:  Pipe, gate or butterfly valve, valve box, tee, reducer, thrust block, elbow, pipe cap and miscellaneous fittings, all as specified elsewhere in these Specifications.

B. Valve Box:

1. Applicability: For all buried gate or butterfly valves.

2. Manufacturer: As allowed by the Jurisdiction or specified in the contract documents.

2.3. Type: 

a. In paved areas;, use a slide type.
b. In all other areas;, use a screw extension type.

3.4. Material:  Gray iron.

4.5. Cover:  Gray iron, labeled "WATER"

5.6. Wall Thickness:  3/16-inch, minimum.

6.7. Inside Diameter:  5-inches, minimum.

7.8. Length:  Adequate to bring top to ground surface finish grade, including valve box extensions, if necessary.

8.9. Factory Finish:  Asphalt coating.

9.10. Installation to include valve Valve Box Centering Ring: Include in installation.

C. Incidental Items: Valve Stem Extension: For all buried valves, provide as necessary to raise 2-inch operating nut to within 3 feet of the finish grade. Stem diameter per valve manufacturer's recommendations, but not less than 1 inch.

1. Valve Stem Extension:  Provide for all buried valves.  Raise 2-inch operating nut to within two feet of, but not closer than 6 inches of the surface.  Stem diameter per valve manufacturer's recommendations, but not less than 1 inch.

2. Other Items:  As required to complete the installation in accordance with the Plans.

PART 3 - EXECUTION

3.01  GENERAL

A. Install only approved materials.

B.A. Install in accordance with the Plans, according to the contract documents the Standard Drawings, and the Jurisdictional Engineer's instructions, as appropriate.

D.B. Apply polyethylene wrap to all iron pipe, valves, valve boxes, fire hydrants, and fittings.

E.C. Set tops of valve boxes to finish grade unless otherwise directed by the Jurisdictional Engineer.

F.D. Check the working order of all valves by opening and closing through entire range.  Before exercising opening the valves, check with the Jurisdiction on operating requirements.

C.E. Test and disinfect all valves, fire hydrants, and appurtenances as components of the completed water main in accordance with according to Section 5030.

3.02 FLUSHING DEVICE (BLOWOFF)

A. Install where shown on the plans, in accordance with Figures 5020.2 and  5020.3 and construct as specified.

 1. Install gravel backfill.

 2. Install thrust block, bearing on perpendicular excavation face of undisturbed earth.

B. Temporary locations to be used only where approved by Jurisdictional Engineer.  Temporary blowoff must be removed prior to project completion and acceptance.

3.03 FIRE HYDRANT

A. Install according to Figure 5020.1.

A.B. If the auxiliary fire hydrant valve is positioned adjacent to the water main, attach it to an anchoring anchor tee.

B.C. If the auxiliary fire hydrant valve is positioned away from the water main, restrain all joints between the valve and water main.

C. Position auxiliary valve at least 15 inches (clearance) away from fire hydrant.

D. Fire Hydrant Depth Setting:

1. Use adjacent finish grade to determine setting depth.

2. Nozzle not less than 1' -6" nor more than 1'-11" above grade, measured from centerline of nozzle to grade.  Adjust barrel length, or add or remove extensions as required.

2. Set bottom of breakaway flange between 2 and 5 inches above finish grade.

3. If finish grade is not to be obtained completed during the current project, consult with the Jurisdiction Engineer for proper setting dimension depth.

E. Coordinate installation with tracer wire installation.

F. Refer to Figure 5020.1.

G.F. Orient fire hydrant nozzles as directed by the Jurisdiction Engineer.

END OF SECTION