HDPE Pipe Assembly Statement of Work - IDEAS-EC

CEDAR VIEW DAM
Outlet Works Rehabilitation
HDPE Pipe Assembly Statement of Work
April 2009
Prepared by: US Bureau of Reclamation
1

HDPE Pipe Assembly Statement of Work
BACKGROUND
Cedar View Dam is an off stream reservoir that was originally constructed to provide irrigation
storage for downstream farms. The reservoir was transferred from the irrigators to the Ute
Indian Tribe in the 1960s and the dam crest was raised approximately 15-feet, to the present top
elevation of 8036. No drawings can be found for the 1960s changes. A downstream berm was
also added at that time to allow for the additional height of the dam. Rudimentary investigation
information has been found, as well as limited original drawings. Actual dam construction
differed from the original drawings in that the outlet gate is located downstream of the dam axis,
rather than at the upstream inlet as shown on the original drawings. A square concrete outlet
pipe extension was constructed in the 1960s to allow construction of the downstream beam. No
information has been found on the borrow source for the dam. Hydraulic height of the existing
dam is approximately 32-feet.
The Ute Indian Tribe has asked Reclamation to minimize the seepage out of the reservoir
through the basin and dam to maintain water levels for recreation and fish habitat. Cedar View
Dam is currently used for recreation by the Ute Indian Tribe.
The reservoir was drained in August 2008 to begin rehabilitation of the dam and expose the
outlet works. Upon examination of the outlet works it was concluded that due to the deteriorated
condition of the original concrete encased corrugated metal pipe the conduit needed to be sliplined
with HDPE pipe, and the annular space grouted.
SITE LOCATION
Cedar View Dam is located northwest of the towns of Neola and Roosevelt, Utah in the central
area of the south side of the High Uinta Mountains. The dam sits between Cottonwood Creek
and the Uinta River drainages, at latitude 40°33’18.15”, Longitude 110°8’0.41”. Figure 1 shows
the location of the Dam and Reservoir feature in relation to Roosevelt.
2

Cedar View Dam
Figure 1 - Cedar View Dam and Reservoir in northeastern Utah with respect to Roosevelt,
Utah. Not to scale.
SUMMARY OF WORK
1. Deliver specified HDPE pipe, IPS back-up ring, two 18-inch flanged adaptors, one 18-
inch electrofusion couplers, and pipe block centralizers to construction site.
2. Deliver all equipment necessary to assemble HDPE to construction site.
3. Assemble HDPE outlet conduit.
4. Extrusion weld grout delivery lines as indicated in attachment 3.
5. Extrusion weld pipe block centralizers as indicated in attachment 3.
6. Close-out project.
Note: After each section of pipe is welded, the government construction crew will insert a
portion of the pipe into the existing outlet pipe, until the HDPE extends completely through the
existing concrete encased CMP.
3

Pipe Summary Table:
Description Quantity Unit
18-inch ID IPS Backup Ring (ANSI Drilling Straddle Center) 1 Each
18-inch electrofusion coupler 1 Each
Main 18-inch HDPE DR 32.5 Pipe 260 LF
18-inch IPS Fittings Flange Adapter DR 32.5 2 Each
Grout Pipe No. 1 – 1.5 inch 230 LF
Grout Pipe No. 2 – 1.5 inch 200 LF
Grout Pipe No. 3 – 1.5 inch 170 LF
Grout Pipe No. 4 – 1.5 inch 140 LF
Grout Pipe No. 5 – 1.5 inch 110 LF
Grout Pipe No. 6 – 1.5 inch 80 LF
Grout Pipe No. 7 – 1.5 inch 50 LF
Grout Pipe No. 8 – 1.5 inch 30 LF
Block Centralizers/Skid Plates 144 Each
*HDPE pipe shall be single and smooth wall, and pressure rated
1 2
Figure 1 – Example of IPS Fittings Flange Adapter
Figure 2 – Example of IPS Backup Ring. Bolt holes shall be ANSI Drilling Straddle
Center
4

GENERAL REQUIREMENTS
Safety
Personnel shall adhere to Reclamation’s Safety and Health Standards during the performance of
the work.
A job hazard safety analysis shall be written for the specific work and reviewed with personnel
working on the job.
Utilities
There are no known utilities near the site.
Use of Land
Care shall be taken to limit impact to land adjacent to construction area. Care shall be taken to
limit noise and air pollution on the property. Pollution of the land and water from oils, fuel and
other hazardous materials shall be avoided at all costs.
SITEWORK
The site will be cleared and graded by the government to provide necessary work space for pipe
assembly and storage.
SITE ACCESS
Access to the site shall be limited to existing roadways. A permit is required to enter Native
American land. Necessary permits will be provided by the government.
HDPE PRESSURE PIPE
HDPE pipe shall meet the following specifications
PART 1
GENERAL
1.01 MEASUREMENT AND PAYMENT
A. Measurement: Length along pipe centerline between ends of pipe in place.
Continuous through fittings with no allowance for lap at joints.
5

B. Payment: Applicable linear foot price. Includes cost of furnishing materials;
manufacturing and assembling pipe; Extrusion welding centralizers and grout
delivery lines: and furnishing warranty bond.
1.02 REFERENCES
A. ASTM International (ASTM)
1. ASTM A 193-06 Standard Specification for Alloy-
Steel and Stainless Steel Bolting Materials for High-
Temperature Service.
2. ASTM A 536-84(2004) Standard Specification for
Ductile Iron Castings.
3. ASTM D 638-03 Standard Test Method for Tensile
Properties of Plastics.
4. ASTM D 2657-03 Standard Practice for Heat Fusion
Joining of Polyolefin Pipe and Fittings
5. ASTM D 2774-04e1 Standard Practice for Underground
Installation of Thermoplastic Pressure Piping.
6. ASTM D 3261-03 Standard Specification for Butt Heat
Fusion Polyethylene Plastic Fitting for Polyethylene Pipe
and Tubing.
7. ASTM D 3350-05 Standard Specification for
Polyethylene Plastics Pipe and Fittings Materials.
8. ASTM E 165-02 Liquid Penetrant Examination
9. ASTM F 412-06 Terminology Relating to Plastic
Piping Systems
10. ASTM F 714-06 Standard Specification for
Polyethylene (PE) Pipe (SDR-PR) Based on Outside
Diameter.
11. ASTM F 2206-02 Fabricated Fittings of Butt-Fused
Polyethylene (PE) Plastic Pipe, Fittings, Sheet Stock, Plate
Stock, or Block Stock
B. American Water Works Association (AWWA)
1.03 SUBMITTALS
A. Pipe and Fittings:
1. AWWA C906-99 Polyethylene (PE) Pressure Pipe and
Fittings, 4 in. (100mm) Through 63 in. (1,575 mm), For
Water Distribution and Transmission
6

B. Fusion procedures:
1. Catalog information confirming pipe, fittings, and other
materials conform to requirements of this Section.
1. Fusion temperature.
2. Interface pressure.
3. Cooling time.
C. Equipment data: Submit data for fusion welding equipment.
1.04 QUALIFICATIONS
A. Pipe Manufacturer: Listed with Plastic Pipe Institute as meeting recipe and
mixing requirements of resin manufacturer for resin used to manufacture pipe for
this Project.
B. Person fusing HDPE pipe shall be certified under 49 CFR § 192.285, have
minimum of 1 year of experience with fusing HDPE pipe in accordance with
recommendations of pipe supplier or fusing equipment supplier.
1.05 DELIVERY, STORAGE, AND HANDLING
A. Prevent damage to pipe and fittings during loading, transporting, unloading,
storing, and laying.
B. Shipping: Do not cut, kink, or otherwise damage pipe during transportation.
C. Maintaining circularity of pipe 18 inches in diameter and larger.
1. Before shipping, install internal supports in pipe to
maintain circularity.
2. Supports:
a. Two members at 90 degrees to each other.
b.Minimum member cross section: Nominal 2- by 4-
inches.
3. Place supports at 5 feet from ends of each pipe section.
4. Orient support legs in same axis along pipe centerline.
5. Where necessary due to ground conditions, store pipe on
wooden sleepers, spaced suitable and of such widths as not
to allow deformation of pipe at point of contact with
sleeper or between supports.
7

D. Transport fittings with padded bolsters between the pipes. Use heavy padding
under ties.
E. Do not store HDPE pipe in unprotected, outside storage for more than 2 years.
PART 2
PRODUCTS
2.01 PIPE
A. HDPE Pressure Pipe: AWWA C 906, except;
2.02 MATERIALS
1. PE material:
a. Standard PE code designation: PE 3408.
b.Minimum cell Classification, ASTM D 3350: PE
334434C, or E.
A. Polyethylene resin shall meet or exceed requirements of ASTM D3350 for PE
3408 material with cell classification of 335434C, or better.
B. Maximum Allowable Hoop Stress: 800 psi at 73.4 degrees F.
C. Pipe sizes shall conform to ASTM F714.
D. Pipe and fittings shall have a Standard Dimension Ratio (SDR) as shown on the
Drawings.
2.03 THERMAL BUTT FUSION
A. Pipe lengths, fittings, and flanged connections to be joined by thermal butt-fusion
shall be of same type, grade, and class of polyethylene compound and supplied
from same raw material supplier.
2.04 FITTINGS
A. Tees, crosses, tapers, adaptors, couplings, bends, and connections at structures
and encasements: Fabricated from HDPE for sizes 8 inch and larger, by means of
thermal butt-fusion. Ends of fabricated fittings shall not be trimmed to match
pipe section to which they are going to be joined. Polyethylene fittings shall have
same or higher pressure rating as pipe when installed, unless otherwise specified,
or as shown on drawings.
B. HDPE fittings: In accordance with AWWA C906, ASTM F 2206, and as shown
on drawings.
1. Material: PE3408.
8

C. Metal back-up flange:
2.05 SOURCE QUALITY CONTROL
1. Material: Ductile iron, Class 150, ANSI B16.1/B16.5, coat
in accordance with manufacturer’s recommendation.
A. HDPE Fittings:
1. Test HDPE fittings in accordance with AWWA C906.
2.06 QUALITY ASSURANCE
A. Acceptance of material delivered to the site shall be subject to approval by the
government.
PART 3
EXECUTION
3.01 PIPE ASSEMBLY
A. Joining Pipe:
1. Make heat fusion joint in accordance with
recommendations of ASTM D 2657 using a Data Logger to
record activity.
2. Pipe shall be joined completely prior to insertion of any
part into the existing conduit. Pipe shall be supported and
handled in a manner that prevents damage.
3. After joining operations are completed clean inside of pipe
and remove debris.
3.02 EXTRUSION WELDING
A. Welding Conduit Centralizers and Grout Delivery Feed Lines.
1. Weld conduit centralizers and grout delivery feed lines in
accordance with recommendations of ASTM D 3261.
3.03 TESTING AND INSPECTION
A. All heat fusion joints to be recorded on a data logger and results given to
Contracting Officer’s Representative.
B. Joint and Mandrel Testing:
1. Joint:
a. Test Procedure: ASTM D638
9

2. Mandrel:
b.Specimens: Cut pipe 12 inches on each side of field
made joint. Rejoin ends and proceed with Work
c. Test Frequency:
1) One joint selected at random by Contracting
Officer’s Representative.
2) Each Test Failure: Two additional joints
selected at random by Contracting Officer’s
Representative.
a. Mandrel test pipeline.
b.Mandrel Configuration: Rigid, with circular crosssection
of diameter not less than 92 percent of
average inside diameter of pipeline and with length
of circular portion equal to nominal diameter of
pipeline.
c. Pulling Method: Manually, by hand.
PROJECT CLOSEOUT
Remove all equipment from construction site. Remove excess pipe and other pipe assembly
related debris.
ATTACHMENTS
Attachment 1 – Dam and Spillway Plan
Attachment 2 – Maximum Embankment Cross-Section
Attachment 3 – Grout Delivery Line Orientation and Slip-Line Details
10