SECTION 16402

UNDERGROUND DISTRIBUTION SYSTEM

PART 1 – GENERAL

1.01 DESCRIPTION:

A. Provide complete underground distribution system as indicated and specified.

B. Conform to lines, grades, elevations, and dimensions. Resolve interferences with other
underground conduit and piping or equipment. Match components suitable for proper
installation.

C. Provide concrete encasement of duct system. Include forms and reinforcing in

installation.

D. Provide cast-in-place or pre-cast manholes and handholes complete with ground rods,
windows, ladders, frames, covers, cable racks, supports, pulling irons, and other inserts.
Use reinforced concrete.

E. Provide Schedule 40 polyvinylchloride (PVC) conduits for power and control circuits
within concrete encased ductbank system. Provide rigid galvanized steel conduits for
instrumentation, communication, I/O, fire alarm and data highway cable circuits within a
concrete encased ductbank system.

1.02 RELATED WORK:

A. Division 1: General Requirements

B. Section 16050: Electrical Work - General

C. Section 16110: Electrical Raceway System

D. Section 16120: Electric Wires and Cables

E. Section 16450: Grounding

F. Section 16998: Field Inspection and Acceptance Testing

1.03 REFERENCES - As specified herein or equivalent IEC or BS Standards::

A. National Electrical Code.

B. National Electric Safety Code.

Libya Infrastructure Master Spec 16402-1 20-Nov-08

 C. Equivalent British/European codes and standards may be used; however, the equivalency
shall be demonstrated and submitted by the Contractor and approved by the CM/CS.

1.04 SUBMITTALS:

A. Shop Drawings: Submit the following in accordance with Section 01300 -

SUBMITTALS:

1. Submit shop drawings and manufacturers' product data for all components and
materials used in the construction of underground distribution systems in
accordance with requirements of Section 16050.

2. Manhole and handhole buoyancy calculations.

3. Provide "As-Built" drawings of underground ductbank system in accordance with

Section 01300.

1.05 DELIVERY, STORAGE AND HANDLING:

A. Provide delivery, storage, and handling of equipment and materials in accordance with
Section 01610.

1.06 QUALITY ASSURANCE:

A. Provide in accordance with Section 01400.

1.07 SEISMIC DESIGN REQUIREMENTS:

A. Conform to the requirements indicated on the structural drawing S-1 and as specified in
Section 01900.

PART 2 - PRODUCTS

2.01 MANUFACTURERS:

A. Polyvinylchloride (PVC) Conduit:

1. Specified in Section 16110.

B. Rigid Steel Conduit, Galvanized:

1. Specified in Section 16110.

C. Manhole Waterproofing Material:

1. Heavy Duty Black, No. 46-449, by Tnemec Company, Inc.

Libya Infrastructure Master Spec 16402-2 20-Nov-08

 2. Hi-Build Bituminous Coating, No. 64-J-5, by Valspar Corporation.

3. Bitumastic Super Service Black, by Kop-Coat, Inc.

4. Or equal.

D. Concrete Red Pigment:

1. Pulverized natural Iron Ore, Number 302 by DCS.

2. Red Iron Oxide Pigment by Bayer Corporation.

3. Red Iron Oxide Pigment by Davis Colors by Beltville.

4. Or equal.

2.02 MATERIALS AND COMPONENTS:

A. Conduit Spacers: Furnish conduit spacers made of plastic to maintain spacing between
conduits.

B. Concrete: Minimum compressive strength, 4,000 psi.

C. Hot-dipped galvanized steel conduit used underground to be painted with bituminous

paint.

D. Manhole Frames and Covers:

1. Heavy duty gray cast iron capable of withstanding a 20-ton wheel load transferred
through dual rubber tires.

2. Conform to details indicated on the drawings and as specified.

3. Provide machine-finished seat.

4. Mark "ELECTRICAL" on cover of manhole unless otherwise specified on

Drawings.

E. Cable Supports in Manholes and Handholes:

1. Cable racks, stainless steel.

2. Cable supports, stainless steel.

3. Insulators, high grade dry-process porcelain with smooth-glazed surfaces.

Libya Infrastructure Master Spec 16402-3 20-Nov-08

PART 3 - EXECUTION

3.01 GENERAL:

A. Perform work in accordance with the National Electrical Code and project drawings.

3.02 INSTALLATION OF CONDUITS:

A. Lay conduits, indicated to be direct buried in the ground, in trench on 3-inch (76.2 mm_
bed of sand and cover with an equivalent 3-inch (76.2 mm) bed of sand. Ensure that no
rocks come in contact with conduit during backfilling. Dig trenches to depth and location
indicated.

B. Provide minimum separation of power and control conduits of 3 inches (76.2 mm) both
vertically and horizontally. Build ductbank layer by layer, backfill and compact each
layer to provide support for next layer.

C. Separate power and control ducts from instrument telephone, fire alarm and signal ducts
by a minimum of 12 inches (304.8 mm).

D. Backfill ductbank in layers and tamp or puddle as indicated in Section 02210. Provide
yellow ductbank marker tapes, reading "Caution - Electrical Lines Below", over entire
length of ductline. Locate tapes 12 inches (304.8 mm) below grade. Provide a tape for
every 12 inches (304.8 mm) of width of ductline.

E. Install conduit, encased in concrete with spacers and reinforcing, as specified. Rigid
galvanized steel conduits to be painted with bituminous paint.

F. Install conduit runs following routing on drawing and running in straight lines. Provide
end bells where ducts enter manholes or handholes of the same material as the duct
system. Where deviation from a straight line becomes necessary, install bends of radius
which allow for rodding and installation of cable.

G. Accomplish changes in direction of runs exceeding total of 10 degrees, either vertical or

horizontal, by long sweep bends having minimum radius of curvature of 25 ft (7.6 m).
Manufactured bends can be used at ends of short runs of 100-ft (30.5 m). or less, and then
only at or close to the end of run. Provide long sweep bends made up of one or more
curved or straight sections and/or combinations thereof. Install manufactured bends with
minimum radius of 36-in (914.4 mm). where larger radius cannot be used.

H. Lay ductlines to minimum slope of 4 inches per 100-ft (30.5 m). and slope to manholes
and handholes from a high point between the manholes and handholes. Ductlines are to
slope away from buildings.

Libya Infrastructure Master Spec 16402-4 20-Nov-08

 I. Install spacers at intervals of approximately 4 ft. (1.2 m) and stagger between tiers of
ducts to provide not less than 12-in (304.8 m). of longitudinal separation. Install base
spacers to provide at least 3-in (76.2 mm). between bottom of trench and underside of
bottom conduits. Completely fill space with concrete. Firmly wire conduits and spacers
together before concrete is placed.

J. Ductbanks are to be formed, unless trench conditions allow for neat placement of
concrete with specified clearances.

K. Prior to placing of concrete, remove all dirt, sand, and any other debris from between
conduits and from trench bottoms. Hold conduits in place to prevent floating or
accidental movement.

L. Stagger joints in conduits at least 6-in (152.4 mm). Do not allow couplings to rest on
bottom of trench. Install couplings for plastic conduit in accordance with manufacturer's
recommendations.

M. Install concrete encasements so minimum clearance of 12-in (304.8 mm). from concrete
to parallel pipes, lines, structures, etc., is maintained. Where ducts cross, minimum
clearance of 6 inches (152.4 mm) is required. Do not allow the top of concrete to be less
than 30-in (762 mm). below finished grade or paving. Submit special conditions which
may require lesser clearances or special conditions which may require greater than 30
inch (762 mm) depth for approval.

N. Where a connection is made to existing ductline, bond or dowel concrete encasement to

existing encasement. Use waterstop between ductpours and between manholes or
buildings and ductwork as indicated.

O. Do not use power-driven vibrators for spading of concrete around ducts.

P. Roll and grade backfill, and restore surface to condition equal to the site finish grade, or
as otherwise indicated.

Q. Keep conduits clean of concrete, dirt, and other substances during the course of
construction. After the ductlines have been completed, pull a standard flexible mandrel
not less than 12-in. (1.2 m) long, having a diameter approximately 1/4-in. (6.35 mm) less
than the inside diameter of the conduit, through each conduit, after which pull a brush
with stiff bristles through each conduit to make certain that no particles of earth, sand, or
gravel have been left in the line. Replace conduit runs that do not allow the passage of
the mandrel. Pneumatic rodding may be used to draw in the lead wire. Install in spare
conduits a pull wire or rope, and plug and seal spare conduits after cleaning.

R. Trowel Conduit Red pigment into the top of all ductbanks. Resulting surface is to be
uniform in both texture and the color red. Blend 5 pounds of red ironoxide pigment with
94 pounds of cement and apply to freshly poured concrete surface after screeding.
Trowel the pigment into the cement.

Libya Infrastructure Master Spec 16402-5 20-Nov-08

3.03 MANHOLES AND HANDHOLES:

A. Construct manholes and handholes of 4,000 psi concrete cast in place or pre-cast.

B. Install manholes with cable racks, hooks, insulators, and other features, as indicated.

C. Place a minimum 8 inch (203.2 mm) compacted sand base under each manhole and
handhole.

D. Construct cast-in-place manholes and handholes with forms, complete with centering
cores and molds, to conform to shape, form, line, and grade required and maintain
sufficiently rigid to prevent deformation under load. Make all joints leakproof and
arrange horizontally or vertically. Place forms on successive units for continuous
surfaces and fit to accurate alignment, assuring a smooth completed surface, free from
irregularities.

E. At convenient point close to wall, drive a ground rod into earth. Extend ground rod
approximately 6-in. (152.4 mm) above finished manhole and handhole floor. After
completion of manhole or handhole, connect 6 foot length of No. 4 bare copper ground
wire to ground rod. Connect grounding bushings, cable racks, covers, other metallic
parts, splices, and ground wire installed with each feeder to ground loop.

F. Size space, and place reinforcing bars as indicated and as specified.

G. Set manhole and handhole frames to the required grade, in full bed of concrete mortar to
make watertight connection.

H. Install tops of manhole and handhole covers in unpaved areas approximately 1/2-in. (12.7
mm) above finished grade, and in paved areas install flush with finished surface of
paving.

I. Install 316 stainless steel corrosion-resistant channel support, with continuous slot and
required fittings designed for concrete encasement.

J. Install inserts in the manholes as indicated.

K. Install two cable pulling irons in wall opposite each ductbank entrance into manhole, one
6-in. (152.4 mm) above floor and one 6-in. (152.4 mm) below the roof of manhole.
Where indicated on drawings, install additional features such as openings in manhole
walls for future conduit entrances. Seal future entrances with required courses of brick.

L. Where ductlines enter manholes, terminate conduits in end bells. Terminate steel conduit
entering manholes and handholes in grounding bushing.

Libya Infrastructure Master Spec 16402-6 20-Nov-08

 M. Manhole and handhole frames and covers shall be capable of withstanding a 20-tone
wheel load transferred through dual rubber tires.

N. Manhole and handhole covers shall be marked “Electrical”.

3.04 MANHOLE AND HANDHOLE WATERPROOFING:

A. Apply two coats of bituminous waterproofing material to exterior surfaces of manholes

and handholes. Apply by brush or spray, in accordance with manufacturer's printed
instructions. Allow time between coats to permit sufficient drying.

1. Two coats applied with a minimum dry film thickness of 12 to 14 mils per coat.

3.05 RECORD DRAWINGS OF UNDERGROUND WORK:

A. Furnish two sets of marked copies of contract drawings, showing exact routing and
depths of all underground conduit, duct handholes and manholes. Furnish scaled plot
plans, showing principal outline of buildings and structures. Reference conduits, ducts,
and manholes, and all bends deviating from straight line, dimensionally from fixed
objects or structures.

END OF SECTION

Libya Infrastructure Master Spec 16402-7 20-Nov-08