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. PRECAST CONCRETE CATCH BASINS, DETENTION BASINS BOX CULVERTS & MANHOLES 02722 - 1 12/05/14 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. PRECAST CONCRETE CATCH BASINS, DETENTION BASINS BOX CULVERTS & MANHOLES 02722 - 2 12/05/14 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 PRECAST CONCRETE CATCH BASINS, DETENTION BASINS BOX CULVERTS & MANHOLES 02722 - 3 12/05/14 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 PRECAST CONCRETE CATCH BASINS, DETENTION BASINS BOX CULVERTS & MANHOLES 02722 - 4 12/05/14 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 PRECAST CONCRETE CATCH BASINS, DETENTION BASINS BOX CULVERTS & MANHOLES 02722 - 5 12/05/14 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 PRECAST CONCRETE CATCH BASINS, DETENTION BASINS BOX CULVERTS & MANHOLES 02722 - 6 12/05/14 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. PRECAST CONCRETE CATCH BASINS, DETENTION BASINS BOX CULVERTS & MANHOLES 02722 - 7 12/05/14 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 PRECAST CONCRETE CATCH BASINS, DETENTION BASINS BOX CULVERTS & MANHOLES 02722 - 8 12/05/14 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. PRECAST CONCRETE CATCH BASINS, DETENTION BASINS BOX CULVERTS & MANHOLES 02722 - 9 12/05/14 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 PRECAST CONCRETE CATCH BASINS, DETENTION BASINS BOX CULVERTS & MANHOLES 02722 - 10 12/05/14 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 PRECAST CONCRETE CATCH BASINS, DETENTION BASINS BOX CULVERTS & MANHOLES 02722 - 11 12/05/14 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 PRECAST CONCRETE CATCH BASINS, DETENTION BASINS BOX CULVERTS & MANHOLES 02722 - 12 12/05/14 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 PRECAST CONCRETE CATCH BASINS, DETENTION BASINS BOX CULVERTS & MANHOLES 02722 - 13