12/05/14
DESIGN NO. _____
SECTION 02722
PRECAST CONCRETE CATCH BASINS, DETENTION BASINS, BOX CULVERTS AND
MANHOLES
PART 1 - GENERAL
1.01 DESCRIPTION OF WORK
A.
Provide precast concrete catch basins, detention basins,
box culverts and manholes as indicated on the Drawings
and as specified herein. Subsequently, in this Section,
these items will be referred to as "precast units".
B.
Provide all frames, covers, traps, steps/rungs, and other
miscellaneous items to be fabricated with or installed on
the precast units.
1
1.02 RELATED SECTIONS
A.
Cast-in-Place Concrete ..............
Section 03300
B.
Grouting.............................
Section 03610
1.03 REFERENCES
A.
American Society for Testing and Materials (ASTM)
B.
Federal Specifications (FS)
C.
American Association of State Highway and Transportation
Officials (AASHTO)
D.
Standard Sewer Specifications – The City of New York,
Department of Design and Construction, Division of
Infrastructure (NYC DDC)
E.
Sewer Design Standards - The City of New York City,
Department of Environmental Protection (NYC DEP)
F.
International Concrete Repair Institute (ICRI)
1.04 DESIGN REQUIREMENTS
A.
NYCSCA
Precast units shall meet NYC DEP requirements and be
capable of withstanding an AASHTO HS20 loading.
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B.
DESIGN NO. _____
Precast units shall be manufactured using normal weight
concrete with a minimum compressive strength of 4000 psi,
air-entrained, and a maximum water to cement ratio of 0.42
as per Class 40 concrete of the NYC DDC Standard Sewer
Specification.
1.05 SUBMITTALS
A.
Product Data
Submit manufacturer’s product data on each of the
following:
B.
1.
Each type of cast iron cover and frame
2.
Each type of step/rung
3.
Trap
4.
Butyl Gasket
5.
Coating
Shop Drawings
Before casting units, submit shop drawings of each item
to be cast, showing details of all pipe entries, finish
grades and other pertinent information.
Ensure the
orientation of the catch basin properly accounts for the
required grating slot direction.
C.
NYCSCA
Quality Control Submittals
1.
Design Data:
Submit design mixes for concrete,
including list of admixtures to be used, and
preliminary trial mix test results.
2.
Test Reports:
3.
Certification:
From testing laboratory that
construction of the precast units is in compliance
with the requirements of NYC DDC and DEP and this
specification.
4.
Contractor Qualifications:
Provide proof of
Manufacturer and Concrete Laboratory qualifications
specified under “Quality Assurance”.
Daily testing logs.
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DESIGN NO. _____
1.06 QUALITY ASSURANCE
A.
Qualifications
1.
Precast Unit Manufacturer: Company specializing
in the production of precast concrete site
structures shall have a minimum of five years
experience.
2.
Concrete Laboratory: Concrete laboratory
providing design mixes and quality control
inspection shall be New York City licensed and
shall meet the requirements of ASTM E329.
1.07 DELIVERY, STORAGE AND HANDLING
A.
Deliver, store, and handle precast units in such manner
so as not to damage the units.
PART 2 - PRODUCT
2.01 MANUFACTURERS
A.
B.
C.
NYCSCA
Precast Units
1.
Afco Precast Corp., Middle Island, NY 11953
2.
Coastal Pipeline Products Corp., Calverton, NY
11933
Coatings
1.
Tnemec Company, Inc.
Kansas City, MO 64141
2.
Carboline Company
St. Louis, MO 63144
3.
Sherwin Williams Corp.
Cleveland, OH 44101
4.
M. A. B. Paint
Broomall, PA
5.
Mercury Paint Corp.
Brooklyn, NY 11203
19008.
Cast Iron Frames and Covers
1.
Campbell Foundry Co.
Harrison NJ
07029
2.
Neenah Foundry Co.
Neenah WI 54956
3.
McKinley Iron Works, Inc. Worth TX
76101
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D.
E.
F.
DESIGN NO. _____
Precast Unit Steps/Rungs
1.
Campbell Foundry Co.
Harrison NJ
07029
2.
Neenah Foundry Co.
Neenah WI 54956
3.
McKinley Iron Works, Inc. Worth TX
4.
M.A. Industries Inc.
76101
Peach Tree City, GA 30269
Self-sealing Butyl Gasket
1.
Hamilton Kent
Kent, OH 44240
2.
Allstate Gasket & Packing, Inc.Hicksville, NY 11801
3.
Darcoid Co., Inc.
Hicksville, NY 11801
Expansion Screw Anchors
1.
Simpson Strong-Tie Co., Inc.
Addison, IL 60101
2.
Powers Fastening, Inc.
New Rochelle, NY
10802
3.
Hilti Corp.
Tulsa, OK 21148
2.02 MATERIALS
A.
Cement
Shall conform to ASTM C150, Type II, and shall be of the
non air-entrained types:
B.
NYCSCA
Admixtures
1.
The use of admixtures shall comply with the
requirements of Section BC 1903.6 of the 2014 NYC
Building Code. The final soluble chloride content
in concrete, percent by weight of cement, due to the
addition of admixtures and other ingredients shall
not exceed .05 at 28 days.
2.
Air-entraining
C260.
3.
Chemical admixtures shall conform to ASTM C494.
admixtures
shall
conform
to
ASTM
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DESIGN NO. _____
4.
C.
Slag cement:
ASTM C989, Grade 100 or 120.
The
amount of slag in the concrete mix may be up to 40%
of the cementitious content.
Water
Shall be clean potable water free of injurious foreign
matter conforming to the requirements for water specified
in ASTM C94.
D.
Aggregates
Fine and coarse aggregates shall be regarded as separate
ingredients. Each size of coarse aggregate, as well as
the combination of sizes when two or more are used, shall
conform to the appropriate grading requirements of the
applicable ASTM specifications. Maximum size of coarse
aggregate shall conform to paragraph 3.3.2 of ACI 318.
Aggregates shall conform to ASTM C33 and be of Size No.67
or No.8.
E.
F.
Concrete Reinforcement
1.
Reinforcing Bars: All reinforcing bars shall be of
deformed type of new billet steel conforming to
current requirements of ASTM A615, grade 60. No
rail or re-rolled steel will be permitted.
2.
Welded Steel Wire Fabric:
Wire Fabric
conform to the requirements of ASTM A185.
shall
Manhole/Detention Basin Frame and Cover
Neenah Foundry Co. #R-1753-A cast iron frame and cover
with Type "G" tightening bar (pentagonal head) or equal
product manufactured by Campbell Foundry or McKinley Iron
Works, Inc. Clear opening to be 27” minimum.
G.
Catch Basin Frame and Cover
Neenah Foundry Co. #R-3573-2Q, cast iron frame and grate,
with Type "G" tightening bar (pentagonal head) or equal
product manufactured by Campbell Foundry or McKinley Iron
Works, Inc. Grate must be ADA compliant.
2
H.
Traps
Neenah Foundry Co. # R-3701 trap, cast iron or equal
product manufactured by Campbell Foundry or McKinley
Iron Works, Inc.
NYCSCA
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I.
J.
DESIGN NO. _____
Precast Unit Steps/rungs:
1.
Campbell Foundry Co. Pattern #2592 (cast iron,
diamond
non-skid
design)
or
equal
product
manufactured by Neenah Foundry or McKinley Iron
Works, Inc. with stainless bolts and washers with
Ackerman-Johnson Expansive Screw Anchors (Cat. No.
762-62, with non-corrosive brass cones) and 1/4inch thick neoprene gaskets.
2.
M.A. Industries Inc. Model PS-4-B copolymer
polypropylene plastic surrounding 1/2-inch diameter
grade 60 reinforcement.
Self-sealing Butyl Gasket
7/8" x 7/8" or 1" diameter
K.
Expansion Screw Anchors with malleable lead shields in
accordance with Federal Specifications FF-S-325C, Group
1, Type 1, Class 1.
L.
Interior Coating
Two component high solids polyamine epoxy or epoxy
polyamide coating in accordance with ANSI/NSF Standard 61
meeting the performance characteristics of Tnemec Series
22 Epoxoline or Carboline Carboguard 888.
3
M.
Exterior Coating
Two component polyamine epoxy or epoxy polyamide coating
meeting the performance characteristics of Tnemec Series
22 Epoxoline or Carboline Carboguard 888.
2.03 MIXES
A.
General
Concrete for all parts of the
specified quality capable of
excessive segregation and, when
all characteristics required by
Drawings.
B.
Work shall be of the
being placed without
hardened, of developing
the Specifications and
Strength
Strength requirements given in Part 1 of this
Specification are based on 28-day compressive strength.
NYCSCA
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C.
DESIGN NO. _____
Provide the following air content for the grading size of
coarse aggregate as follows:
1.
No.8......71/2%
2.
No. 57 or 67.....6%
Tolerance on air content as delivered shall be +1.5%.
2.04 FABRICATION
A.
Fabricate the precast units to the sizes and shapes shown
on the Drawings, with pipe openings, precast collars,
rungs/steps, lift inserts and other items as indicated.
B.
Cast units in tight, well-built forms; vibrate concrete
to ensure smooth, laitance-free surfaces.
C.
Finished units shall be warp-free, of uniform thicknesses
with shapes, sizes, pipe openings, inserts and all other
details as shown on the Drawings and as specified herein.
D.
Provide 5/8" threaded dowels at pipe opening locations to
provide attachment for piping.
E.
Provide scoring for bond on bottom slab of the precast
units as detailed on the Drawings. Provide keys at all
joints.
F.
Opening into unit tops shall be 28” diameter.
2.05 PROTECTIVE COATINGS
A.
Interior coating for precast units
1.
NYCSCA
Surface preparation
a.
Concrete shall have cured a minimum of 28 days
and have a moisture content acceptable to the
coating manufacturer.
b.
Surfaces shall be cleaned free of dust, oil,
grease, laitance, or any other foreign matter.
c.
Surfaces shall be abrasive blasted to provide
an ICRI CSP 5 surface prep.
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DESIGN NO. _____
2.
B.
The epoxy coating is to be applied in two
applications. While the surface preparation is to
be done at the plant, the contractor has the option
of having the first application of the coating done
in the plant or having both applications done in
the field.
Apply at a rate of 4.0 mils DFT per
coat.
Apply in strict accordance with the
manufacturer's recommendations.
Exterior coating for precast units
Provide for units and surfaces specified to receive it.
3
1.
2.
Surface preparation
a.
Concrete shall have cured a minimum of 28 days
and have a moisture content acceptable to the
coating manufacturer.
b.
Surfaces shall be cleaned free of dust, oil,
grease, laitance, or any other foreign matter.
c.
Surfaces shall be abrasive blasted to provide
an ICRI CSP 5 surface prep.
The epoxy coating is to be applied in two
applications. While the surface preparation is to
be done at the plant, the contractor has the option
of having the first application of the coating done
in the plant or having both applications done in the
field. Apply at a rate of 8.0 mils DFT per coat.
Apply in strict accordance with the manufacturer's
recommendations.
2.06 SOURCE QUALITY CONTROL
A.
Special inspection and testing shall be conducted at the
manufacturer's plant by a Testing Laboratory approved by
the Authority.
B.
Special inspection and testing shall be in compliance
with the 2014 New York City Building Code and shall be in
compliance with the standards of construction established
by the Bureau of Sewers for manhole construction, and
shall include, but not be limited to the following
procedures:
NYCSCA
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NYCSCA
DESIGN NO. _____
1.
All testing shall be in accordance with New York
City Building Code requirements and the applicable
ASTM’s.
2.
Perform daily batch plant inspection to ascertain
that proper concrete material gradations are
performed. Sieve both fine and coarse aggregates
to check gradations.
3.
Calculate fineness modulus and percent moisture on
a daily basis.
4.
Verify mill certificates for cement.
5.
Verify mix designs by checking computer printout
tapes or scale measurement proportioning of
materials.
6.
Inspect formwork and reinforcement for manhole,
risers, bases, collars and covers.
7.
Inspect methods and concrete placement.
8.
Prepare a minimum of four concrete cylinders for
each 50 yards batched.
9.
Tag and verify, independently, manholes and catch
basins and ancillary parts with each group of
cylinders.
10.
Tag and report cylinders with corresponding manhole
castings on a daily basis.
11.
Check slump, air content, weight per cubic foot and
temperature for each batch prepared.
12.
Store cylinders in a proper humidified room under
Laboratory's directions.
13.
Inspect and verify that formwork remains intact in
a properly controlled area for 24 hours minimum.
14.
Cap and break cylinders at 7 and 28 days or until
full design strength is achieved.
At that time
break a minimum of two cylinders.
Store the
remaining cylinders prepared in a batch for 28 days
before discarding.
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C.
DESIGN NO. _____
15.
Inspect completed precast unit components for
defects and voids prior to shipment to the jobsite.
16.
Monitor material and finish product handling to
assure that unnecessary vibrations are not imparted
to the cast concrete.
The Contractor shall submit to the Authority before
delivering the precast units to the jobsite, the
following:
1.
Copies of daily logs of the testing laboratory,
indicating pertinent information.
2.
Certification from the testing laboratory that
construction of the precast units is in compliance
with the requirements of the Department of Design
and construction, Division of Infrastructure, and
Department of Environmental Protection of the City
of New York.
PART 3 - EXECUTION
3.01 INSTALLATION
A.
Install precast units at locations shown on the Drawings;
place level and plumb, and to proper depths.
Catch
basins are to be placed to ensure that the long direction
of the slot of the grating will be perpendicular to the
flow of pedestrian traffic.
Coordinate with pipe
connection locations. Install butyl gaskets at joints on
both horizontal surfaces of keyed joint, in such manner
to seal each joint completely, providing adequate lap.
One 9” or less diameter opening per unit is permitted to
be core drilled in the field due to fabrication errors.
Any other unit requiring greater diameter or greater
opening shall be rejected.
B.
Install precast collars and manhole brick set in Type M
mortar to allow for placement of the covers at the
correct rim invert elevation.
C.
Install cast iron frames and covers, and traps, as
detailed on the Drawings and as recommended by the
manufacturer.
Grates are to be placed with the long
direction of the slot perpendicular to the flow of
pedestrian traffic when placed in walkways.
NYCSCA
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D.
E.
DESIGN NO. _____
Units with large spalls (greater than 2” in depth and 2
SF in area) and openings greater than 9” in diameter
placed in the wrong location are rejected and shall be
replaced. Minor spalls and openings 9” or less placed
in the wrong location are to be patched as follows:
a.
Roughen surface or perimeter of opening to a
fractured aggregate surface.
b.
In openings, drill and install a minimum of four
1/2” dia ss expansion anchors with 4” extension.
c.
At openings, install butyl sealant around
perimeter.
d.
Apply slurry coat of hydraulic repair mortar of
type approved by the A/E of Record to all surfaces
to receive repair mortar.
e.
Install hydraulic repair mortar to match existing
contours and thicknesses of members.
After installation of the precast units and before
backfilling, provide protective coatings as follows:
1.
Interior:
If the first coat was applied in the
shop, lightly clean and roughen the surface and
touch up areas of damage with the same coating.
Apply a second coat at 4.0 mils DFT. If both coats
are to be applied in the field, apply each coat at
4.0 mils DFT per coat, allowing the manufacturer’s
recommended cure time between coats. If second coat
is not installed within manufacturer’s specified
time parameters, lightly roughen prior to second
coat.
2.
Exterior, for those surfaces and units designated
to receive it: If the first coat was applied in
the shop, lightly clean and roughen the surface and
touch up areas of damage with the same coating.
Apply a second coat at 8.0 mils DFT. IF both coats
are to be applied in the field, apply each coat at
8.0 mils DFT per coat, allowing the manufacturer’s
recommended cure time between coats.
If second
coat is not installed within manufacturer’s
specified parameters, lightly roughen prior to
second coat.
3
NYCSCA
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F.
DESIGN NO. _____
Make pipe-to-precast unit connections using non-shrink
grout.
END OF SECTION
Notes to Specifier (Delete from Specification)
1.
Revise title and include in list of precast items if other
types of precast units are used on the project, such as dry
wells.
2.
Gratings are to be carefully selected to ensure the “free open
area” is sufficient to take the intended drainage area. The
specified catch basin grating meets ADA requirements for
walkways in accessible routes, as it has a 1/2” opening max.
The free open area of an ADA compliant grating is typically
smaller for a similar diameter grating that is non-ADA
compliant. Ensure that grating slot directions are shown on
Drawings to be perpendicular to the flow of traffic in ADA
accessible routes.
3.
If the precast unit will be subject to cyclical water, such as
the top of a tank in a planted area, or to a corrosive
environment (not typical), specify specifically what units and
what surfaces are to be coated with the exterior coating.
Otherwise, delete the exterior coating and any references to
such from the specification.
HB:WM:hb:GR
NYCSCA
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DESIGN NO. _____
LIST OF SUBMITTALS
SUBMITTAL
DATE SUBMITTED
DATE APPROVED
Product Data:
_______________
_______________
_______________
_______________
1. Each type of cast iron
cover and frame
2. Each type of rung
3. Trap
4. Gasket waterstop
5. Coating
Shop Drawings:
1. Precast Units
Design Data:
_____________
1. Concrete mix
Test Reports:
_____________
1. Daily logs
Certification:
_____________
1. Compliance with
requirements
Qualifications:
_____________
1. Manufacturer
2. Concrete Laboratory
* * *
NYCSCA
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