SECTION 653 – GAS
653.01 Description
The work describes the requirements for installing gas mains, valves, vents, service lines, and gas valve boxes, and resetting gas valve boxes.
653.02 Materials
Provide materials as specified: Coarse Aggregate (No. 57) ................................ ................................ ................................ ............................ 901.03 Soil Aggregate (I-3) ................................ ................................ ................................ ................................ ...... 901.11 Concrete ................................ ................................ ................................ ................................ ....................... 903.03 CLSM ................................ ................................ ................................ ................................ ........................... 903.09 Structural Steel ................................ ................................ ................................ ................................ ............. 906.01 Bolts and Bolting Material ................................ ................................ ................................ ............................ 908.01 Class A Bedding ................................ ................................ ................................ ................................ ...... 909.01.01 Class B Bedding ................................ ................................ ................................ ................................ ...... 909.01.02 Class C Bedding ................................ ................................ ................................ ................................ ...... 909.01.03 Timber for Structures ................................ ................................ ................................ ................................ .... 915.04 Provide steel pipe sleeves as according to ASTM A 252 and galvanize according to ASTM A 123. Provide hot -dip galvanize channel supports, rods, bolts, nuts, washers, inserts, and other hardware required for the permanent installation as according to ASTM A 123 or A 153.
653.03 Construction
653.03.01 Gas Main
A.Prequalification. Only a pre-qualified contractor approved by the Utility may construct or relocate gas mains and appurtenances. The Department will list pre-qualified contractors for this work in the Special Provisions. The work restricted to pre -qualified contractors does not preclude the Contractor from performing sawcutting, pavement removal, removal of excess gas, and temporary or final pavement restoration associated with the work of constructing gas mains. Ensure that the work is performed according to the Utility’s General Specifications.
B.Scheduling Work. Schedule work as specified in 651.03.01.A and according to 49 CFR 192.
C.Handling and Storing. The Utility will provide and deliver pipe in minimum 20 foot lengths, large fittings, and gas protective steel plate. Transport materials within the Project Limits. Coordinate delivery with the Utility Pick up other gas main or service specific materials such as pipe, pipe sleeves, pipe hanger assemblies, expansion joints, and seals between the pipe and sleeves from the Utility at the location specified in the Special Provisions. Store and protect the pipe, and other materials received from the Utility. Support polyethylene pipe every 10 feet during storage and while being transported. Return and deliver excess pipe, fitting, and other miscellaneous materials provided by the Utility to the Utility at the location specified in the Special Provisions. Obtain material receipts from the Utility when material is being d elivered by the Utility or returned to Utility and provide a copy to the RE.
D.Existing Utilities and Structures. Comply with 651.03.01.B.
E.Excavating. Excavate as specified in 202.03.03. Before excavating, sawcut the full depth of the existing pavement and sidewalk. Excavate a trench for placing gas pipe, valves, services, tees, and appurtenances. Obtain RE approval before finishing excavation. If the RE determines that the bottom of the trench is unstable, undercut as directed by the RE and backfill with Class B bedding. If the material at the bottom of the trench is rock or other hard material, excavate an additional 6 inches of the material below the bottom of the pipe. Ensure that trenches are kept free of standing water during the installation. Do not excavate for trenches in embankments until the embankment has been constructed to an elevation of at least 3 feet above the top of the pipe. Do not excavate trenches more than 300 feet in advance of installing the pipe unless approved by the RE. Maintain trenches according to 29 CFR 1926. Provide and maintain trench crossings where necessary. For trenches in the traveled way, shoulder and within 30 feet of the outside edge of the shoulder, backfill and restore the pavement structure and match the surrounding condition before opening to traffic. The Contractor may use temporary protection instead of backfilling trenches in the traveled way and shoulder. If using temporary protection, submit working drawings for approval. For trenches not in the traveled way and shoulder, do not leave trenches open overnight unless protected with caution fence.
F.Installing Gas Mains. Identify areas where pipe will have less than 3 feet of cover. Provide the RE with a report of the identified areas in order to obtain the Utility’s approval. Use a laser system to control the align ment and grade control of the pipe. Place Class B or C bedding and compact with a mechanical tamper using the directed method as specified in 203.03.02.B.3. Install the pipe so that it is solidly supported by the bedding over its full length except where recesses have been made at joint locations. Ensure that interior of the pipe is kept clean and free of all intrusion by bedding, soil, or other foreign ma terial. Install elbows and associated fittings. Cut standard elbows of 45 or 90 degrees to match the required elbow shown on the Plans or as required by field conditions. Install insulating joints, valves, valve risers, valves boxes, miscellaneous fitt ings, insulated locating wire, pipeline markers, and test stations. Maintain a 1 foot minimum clearance between utilities. Coordinate the installation of gas main with other work, and prevent conflicts and interference with existing facilities and proposed construction. Join pipe as follows:
1.Welding Steel Pipe. At least 15 days before installing gas mains, submit to the RE and to the Utility a copy of the welders’ Performance Qualification Record showing the welder has been tested and approved by the Utility. Perform welding according API Standard 1104. Perform welding in a manner that is acceptable to the Utility. Do not tack ground clamps or other devices to the pipe. Repair arc burn damage to the pipe when the depth of the defect is less than 8 percent of the nominal wall thickness by grinding smooth. When the depth of the arc burn physical defect is greater than 8 percent of the nominal wall thickness, remove the defect and the adjacent firth weld. Do not perform welding repairs on gouges, scratches, arc burns or other defects of the pipe. The Contractor may make field repairs of gouges and groves in the parent metal of the pipe by grinding. Do not grind more than 8 percent of the nominal wall t hickness of the pipe. Remove dents that contain stress concentrations, such as scratches, gouges, groves, or arc burns by cutting out the damaged portion of the pipe. Provide an examination of welds by radiographic (X -ray) inspection by a qualified inspec tion company approved by the Utility. Deliver the X-ray films and 1 copy of the radiographic inspection report to the RE and to the Utility. Apply or repair pipe coating so that pipe coating passes a holiday detector test. Seal field welds and fittings with Raychem Unisleeve or with a double layer of cold applied, 4 inch wide, corrosion protective tape as directed by the Utility inspector. Install cathodic protection, including pipe coating, anodes and rectifiers, insulating joints, and test stations. Install the anodes at the lower elevation of the pipe (in or below the water table where possible) and offset the anodes as far as practical from the pipe. Do not place the anodes where other metallic structures such as conduit, cable or pipe is between t he main and the anode. Provide temporary blocking to exposed end of gas mains to be abandoned in place using combination beam and column method. Do not backfill around the anodes with Class B bedding. Use excavated material for backfill around the anodes.
2.Fusing Plastic Pipe. At least 15 days before installing plastic gas mains, submit to the RE and the Utility the names and training qualifications of personnel intended to perform fusing on the work site for approval. Ensure that personnel fusing and inspecting butt fusion joints are certified according to 49 CFR 192. Before fusing plastic pipe, obtain the approval of the Utility for the heat fusion equipment. Fabricate steel to plastic transition fittings using an electric arc welder.
3.Thrust Restraints and Bell Joint Encapsulation. Install thrust restraints and bell joint encapsulation devices as directed by the Utility before excavating other areas around the main. The number of thrust restraints and bell joint encapsulations is dependent upon field conditions and the location of the tie -in and live gas excavations.
4.Hot Tap Preparation. When hot taps are performed by the Utility, in the presence of the Utility’s representative, weld a spherical tee, 3 way tee, line stop fitting or other fitting on the existing steel main, or install a split sleeve collar, line stop fitting or other fitting on the existing cast iron main.
G.Backfilling. Symmetrically backfill on each side of the pipe using Class B bedding in lifts not exceeding 6 inches thick, loose measurement. Co mpact with a flat faced mechanical tamper using the directed method specified in
203.03.02 B.3. When the height of 1 foot above the pipe is achieved, place caution tape. Backfill the remainder of
the trench with suitable excavated material that is free from rock larger than 2 inches in diameter in lifts not exceeding 6 inches thick, loose measurement. Compact with a flat faced mechanical tamper using the directed method as specified in 203.03.02.B.3. For plastic mains with less than 2 feet cover, enclose with steel pipe or protect with a steel plate. If the pipe is in an area not subject to vehicular traffic, the Department will not require a steel plate. Reuse excess excavated material as specified in 202.03.03.C.1. Restore the existing pavement structure to the original condition or as shown on the Plans.
H.Line Stop and Tie-in Assistance. Excavate pits as required to provide access to the Utility for line stops, flow stops, bypass insertions, bagging and venting, hot tops, thrust restraints, purging , and tie -ins. Protect using temporary fencing or steel plates as directed. Maintain the excavation until the Utility has completed its work. Construct a concrete support pad under the pipe at locations requiring a line stop before the arrival of the Utility’s line stop crew. Assist the Utility in handling the pipe by providing sufficient labor and equipment.
I.Tie-in and Gas Out. Perform cutouts and tie-ins at both ends of the pipe simultaneously. The Utility will purge and cut the pipeline. Once started, continue the work of tie-ins until completed. Keep tie-in excavations open or plated as required until the Utility has completed its work. As necessary, modify standard tie -in pieces to fit connection requirements.
J.Air-Pressure Test. Perform an air -pressure test on new pipeline including tie -in pieces under the direction and supervision of the Utility. Perform the test according to the pressures and durations provided in the Special Provisions. Locate and repair leaks in a manner that is approved by the Utility. Pig steel gas mains using a scraper barrel pig or a poly pig when testing plastic mains. Ensure that the pig is in a like new condition that is acceptable to the Utility. If using caps or expansion joints, anchor the pipe in a manner that is acceptable to the Utility to prevent any movement during the test.
653.03.02 Gas Main, Bridge
Install expansion joints in the main as instructed by the Utility representative. Comply with the requirements of 506.03.01 for structural shapes and plates for utility supports. Adjust hangers to provide uniform support of the pipe across the bridge and to align it in the abutment sleeves. Clean and paint the hanger supports as directed by the Utility.
653.03.03 Gas Service Connection
Comply with 651.03.01.B. Perform work associated with the transfer of service including the excavation of 1 tie-in hole for direct burial and transfer installations and 2 tie -in holes for insert installations. Submit to the RE and the Utility the names and training qualifications of personnel intended to install fused or mechanical connections for approval. Turn off the gas at the service tee using pressure control equipment before cutting the existing service pipe. Disconnect the service pipe inside the building before the meter. Support the meter to avoid stressing the house piping. Install services either by inserting plastic tubing in the existing service or by directly burying plastic tubing or pipe.
1.Installing Services with Direct Burial of Plastic Pipe. Excavate as specified in 651.03.01.E. Install the direct burial plastic service including location wire from the main to the building, fuse the pipe, and assist the Utility to tie the connection into the gas main. Backfill above the pipe with Class B bedding in lifts not exceeding 6 inches thick, loose measurement. Compact with a flat faced mechanical tamper. When the height of backfill reaches 2 feet above the service connection, backfill the remainder of the trench with suitable excavated material that is free from rock larger than 2 inches in diameter in lifts not exceeding 6 inches thick, loose measurement. Compact with a flat faced mechanical tamper using the directed method as specified in 203.03.02.B.3. Install a curb shut -off valve and install a meter shut -off valve at the head of the service. Seal the hole in the foundation wall and surround the service pipe with cement or grout. Electrofuse or weld the self tapping tee to the main and connect it to the service using Electrofuse or mechanical fittings.
2.Installing Services by Plastic Tubing Insertion. Excavate and remove any curb shut -off, offset, swing or service drip that may impede the insertion of the plastic pipe. Ream the existin g service from the building to the main. After reaming, air-blow the existing service from the building to the main. Insert the plastic tubing from the main to the building. Install a curb shut -off valve and install meter shut-off valve at the head of t he service. Leave the meter shut off valve open with the plug installed. Electrofuse or weld the self tapping tee to the new main and connect it to the new plastic service using Electrofuse or mechanical fittings. Pressure test the service as required and soap test all fuses and mechanical connections. Perform pressure and soap tests in the presence of the Utility inspector. Release the pressure, tap a self tapping tee, and gas out service through the hose from the meter shut off to the outside of the b uilding until a gas reading of greater than 95 percent is obtained using a combustible gas indicator. Install a tee cap and soap test the cap.
653.03.04 Reset Gas Valve Box
Adjust the height of the existing valve box so that it is set flush with the proposed grade without disturbing the existing valve.
653.03.05 Gas As-Built Plan
Upon completion of the work, submit to the RE and to the Utility as -built drawings in a CADD format acceptable to the Utility.
653.04 Measurement and Payment
The Department will measure and make payment for Items as follows: Item Pay Unit ___" GAS MAIN LINEAR FOOT ___" GAS MAIN, BRIDGE LINEAR FOOT GAS SERVICE CONNECTION UNIT RESET GAS VALVE BOX UNIT GAS AS-BUILT PLAN LUMP SUM The Department will make payment for ___" GAS MAINS by the linear foot including the length projecting into the rear face of the abutment. A unit of GAS SERVICE CONNECTION includes the permanent installation and any required temporary installation for each property.
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Source: Standard Specifications for Road and Bridge Construction, 2019 (rev. 2022-12-21) Edition. Pages 356–360 of 651. View official source ↗