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Understanding Construction Plans and Managing Construction ProjectsPREPARED FOR: New Jersey Water Association 2018 Fall Pre-ConferencePRESENTER: David J. Applegate, P.E., T3, W3

Blueprints vs. Blackline Drawings Mylars vs. Vellums vs. Sepias

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Presentation Outline:Construction Plan Interpretation

Design/Build Documents vs. Design-Bid-Build Documents

Nomenclature Site/Civil Plans

P&ID (Process and Instrumentation Diagram)

Mechanical Plans

07Electrical Plans

08Plumbing/HVAC Plans

Setting the Stage: Pre-construction conference

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Presentation Outline:Construction Management Methodologies

OSHA and Safety

Engineer vs. Contractor expectations

Water main testing

Sanitary sewer gravity main testing

Disinfection and dechlorination of facilities

07Bacteriological testing

08Inspection Reports and Record Keeping

Construction Plan Interpretation

• What is a “blueprint”?

• Old style blueprint utilized a blue background and white drafting.

• New style blueprints utilize a white background and blue drafting.Diazo paper (Starts out yellow)Mylar with drafting is placed over Diazo paperUV light burns through all but drafting; ammonia develops remainder

• What is a “blackline drawing”?

• White background, black drafting.

• Utilizes laser printer technology to produce full size plan sheets.

Blueprints vs. blackprints

Old Style Blueprint

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New Style Blueprint

• What is a blackline drawing? Black drafting on white background. Laser plotter printing on stock white paper.Most common form of engineering drafted plans.Copies made from original blackline drawings.

• Standard sheet sizes 24” (H.) x 36” (L.) 30” (H.) x 42” (L.)

Blackline Drawings

Blackline Sheet

• What is a Mylar®? A stretched polyester (plastic) film; specifically, a resin, Polyethylene

Terephthalate (PET) as manufactured by Dupont.Old days: India ink drafting; Modern days: Laser plotter printing

• What is a vellum?Olden days: a calf skin; Modern days: plasticized rag cotton India ink drafting

• What is a sepia? Photographic paper that develops with a light brown background with

dark brown drafting/linesCheaply reproduces a Mylar or a vellum

• Also, drafting cloth or drafting linen.Muslin woven fabric, using cotton or linen fiber

Mylars vs. Vellums vs. Sepias

Mylar Vellum

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Sepia

• Design-Build (D-B) Plans Tend to be more conceptual in natureDesign detail level usually about 30% Engineer-Contractor partnership to effectuate implementation In theory, D-B team is responsible for any change orders

• Design-Bid-Build (D-B-B) PlansDesign detail at 100% level Engineering duties separate and succinct function Privately or publicly bidContractor is managed by engineerChange orders negotiated

Design/Build Documents vs. Design-Bid-Build Documents

• Show as constructed conditions

• Depict triangulated and/or GPS’d buried facilities (i.e.: valves, services, shut offs) in a GIS format

• May have the titles “As-Built Plans” or “Record Plans”

• Used to “find things” in the future Buried valves Service connections Fittings

As-Built Plans

• DIP = ductile iron pipe

• PVC = polyvinyl chloride

• CPVC = chlorinated polyvinyl chloride

• HDPE = high density polyethylene

• CIP = cast iron pipe

• ACP = asbestos cement pipe

• TCP = terracotta pipe (aka VCP = vitrified clay pipe)

• PCCP = prestressed concrete cylinder pipe

• RCP = reinforced concrete pipe

• CMP = corrugated metal pipe

Nomenclature - Pipes

• FL = flanged

• MJ = mechanical joint

• PE = plain end

• FLxFL = flange by flange

• PExPE = plain end by plain end

• SCH = schedule (i.e.: SCH 40 PVC)

• CTS = copper tube size

• IPS = iron pipe size

• NPS = nominal pipe size

• DN = diameter nominal (metric)

• NPT = national pipe thread

Nomenclature - Fittings

• GV = gate valve• BFV = butterfly valve• BV = ball valve• CV = check valve• PRV = pressure reducing valve• PCV = pump control valve• PRV = pressure reducing valve• RPZ = reduced pressure zone• PSV = pressure sustaining valve• ACV = altitude control valve• NRS = non-rising stem• OS&Y = outside screw (or stem) and yoke

Nomenclature - Valves

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Legend

Scales - Engineering

Scales - Engineering Scales - Architectural

Scales - Architectural Plan View

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Section View

• Reflect everything outside of a building

• Existing topography

• Proposed grading/topography

• Stormwater management

• Landscaping design (planting and lighting)

• Utility and/or yard piping layout

• Soil erosion and sediment control

• Architectural

• Structural

• Construction details

Site/Civil Plans

Topography Topography

Stormwater Management Landscaping - Planting

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Landscaping - Lighting Utility Plans

Utility Plans Utility Profiles

Utility Profiles Utility Profiles

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Soil Erosion and Sediment Control Soil Erosion and Sediment Control

Architectural Architectural

Architectural Architectural

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Architectural Structural

Structural Structural

Construction Details Construction Details

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Construction Details Construction Details

Construction Details

• Depicts the flow pattern of the medium (water, wastewater, air, etc.)

• Reflects interaction of instruments and signals

• Lays out control logic

• Good, all around reference guide to how things work

• Drawing not to scale (NTS)

P&ID (Process and Instrumentation Diagram)

P&ID (cont’d) P&ID (cont’d)

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P&ID (cont’d) P&ID (cont’d)

P&ID – Pressure Transducers – Potable Water P&ID – Pressure Transducers – Potable Water

P&ID – Pressure Transducers – Sanitary Sewer

• Depict building interior water, wastewater, air, etc. moving systems

• Reflect piping lay out and connection types

• Both plan and section views

• Typically utilizes architectural scale

Mechanical Plans

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Mechanical Plans Mechanical Plans

Mechanical Plans Mechanical Plans - Below Grade Structures

Mechanical Plans - Below Grade Structures Mechanical Plans - Below Grade Structures

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Mechanical Plans - Below Grade Structures

Construction Management Methodologies

• Sets the administrative, procedural, and field ground rules.

• Occurs as soon after the contractor signs the project contracts and posts the required performance bonds.

• Attendees: Owner, Engineer, Inspector, Contractor, Local Police Department, other interested parties (utilities affected by construction, regulatory agencies, municipal officials).

• Agenda List of attendees Emergency contact numbers/Lines of communication Schedules (Gantt Chart, project Time of Completion) Submittals (Shop drawings, RFIs, change orders) Safety Payment (Cut off date for monthly partial payment submission)

• Meeting minutes distributed quickly after conference and all attendees provided 7 days to review and comment.

Setting the Stage: Pre-construction conference

The Contractor is responsible for providing the on-site competent person. Neither the Owner nor the Engineer that is representing the Owner is responsible for determining what safe working conditions must be in place. Otherwise, they assume responsibility (and the liability).

An OSHA "competent person" is defined as "one who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them" [29 CFR 1926.32(f)].

The Engineer or their representative can make the Owner aware of unsafe work conditions if the Contractor is unwilling to correct same.

OSHA and Safety

2 – 4 – 5 Rule

Keep everything 2 feet back and away from the edge of trench (excavated materials, spoils, stored equipment, etc.).

When the excavation reaches 4 feet, a safe means of egress must be provided so as to require no more than 25 feet of lateral travel.

When the excavation reaches 5 feet, unless the excavation is in stable rock, shoring must be installed/provided.

OSHA and Safety (cont’d)

Four (4) OSHA Soil Categories:

Stable Rock

• Natural, solid material (i.e.: granite, sandstone) that remains intact when excavated

• Can be excavated with vertical sides

Type A Soils

• Clay, silty clay, sandy clay with unconfined compressive strength greater than 1.5 tons per square foot (tsf)

• No fissures

• No groundwater

• 3/4H:1V slopes allowed up to 20 feet

OSHA and Safety (cont’d)

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Type B Soils

• Cohesive soils (angular gravel, silt, silt loam) with unconfined compressive strength greater than 0.5 tsf but less than of 1.5 tsf

• Fissured Type A soils

• No groundwater

• 1H:1V slopes allowed up to 20 feet

Type C Soils

• Cohesive soils with unconfined compressive strength less than 0.5 tsf

• Groundwater present

• 1.5H:1V slopes allowed up to 20 feet

OSHA and Safety (cont’d) OSHA and Safety (cont’d)

Confined Space• Large enough to enter and do work• Limited/restricted ingress and egress• Not designed for continuous occupancy

Confined Space Entry

Contractors must:• Maintain written and documented training program prior to working

in/around confined spaces• Provide all necessary equipment for entering, including monitoring and

rescue equipment

OSHA and Safety (cont’d) OSHA and Safety (cont’d)

Engineer

• First and foremost, is safeguarding the vested interests of the Owner/Client.

• Places value on a completed product that works as designed, is low maintenance, and free of defects.

• Completion deadlines important.

• Needs to be sympathetic to Contractor’s point of view.

Contractor

• Needs field production.

• Wants to complete the project safely.

• Wants to complete the project on time or before contract deadline.

• Poor or defective products (pipes that leak, pumps that don’t run smoothly (or at all), poor aesthetics) force inefficiencies, which reduce profit and distract from future project availability.

Engineer vs. Contractor expectations

Engineer’s Duties

• Provide full- or part-time construction observation.On most NJDEP/EPA funded projects, f/t inspection required. P/t inspection places onus on Contractor to make field changes.

• Provide construction administration duties. Partial payment review and recommendations. Shop drawing review. Timely review and response to RFIs.

• Serve as communication link between the Contractor and the Owner.

• Provide timely field change or condition design decisions.

Engineer vs. Contractor expectations (cont’d)

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Operator’s Duties

• Act as liaison between Contractor and homeowners.Construction activity timing communication (door hangers).Residence or business access, if necessary.

• Be available to stop or start water and sewer services.Opening or closing of water valves. Shutdown or start up of sanitary sewage pumps. Lock out/tag out activities at treatment plants.

• Direct Engineer on behalf of you, the Owner.

• Provide timely field change or condition decisions.

Engineer vs. Contractor expectations (cont’d)

Contractor’s Duties

• Start and stop construction activities as directed/agreed to. Be aware/sensitive to noise local ordinances. Stop operations and clean up well in advance of stop time.

• Be safe. Abide by all OSHA regs. Provide safe control and/or detouring of traffic. Be aware/sensitive to Owner protocols.

• Take direction from Engineer’s representative.

• Provide timely response to requested field change or condition decisions.

Engineer vs. Contractor expectations (cont’d)

• Hydrostatic (water column) pressure testing only. Safer. Inspector can see water emerging from joints or at ground surface. AWWA Standards (i.e.: C600-17 for DIP) provide template.

• No air (high pressure compressed air) testing allowed!Dangerous. Air cannot been seen, only heard. Air can leak past valves to other parts of the system.No agreed upon standards.

Water main testing Water main testing (cont’d)

AWWA Standard C600-17 computation for allowable water loss:

Water main testing (cont’d)

For 1,200 LF of 12” water main at 150 psi:

Water main testing (cont’d)

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• Properly calibrated pressure gauge capable of reading 1 psi increments.

• Make up water source (typically 55 gallon drum of potable water).Mark the initial water level.Record water level after any make up water is fed.

• Positive displacement pump to feed make up water.

• Be sure that all valves on the line being tested are in the open position.Open right or left? Engineer/inspector to inspect every valve (isolation, intermediate, etc.).

• Valves leading to future connections must be open.

• Hydrant valves must be open.

• Purge water main of all trapped air.

• After 2 hours, if pressure loss is less than 2 psi, and if make up water fed is less than calculated, then the test is a success.

Water main testing checklist

All valves between the gauge and line being tested must be open.

Water main testing (cont’d)

Pounds thrust force (F = pA) exerted on a dead end (end cap, plug):

At 150 psi test pressure on 8” end cap, F = 7,540 pounds

Water main testing (cont’d)

Three methods:

• Low pressure air testing

• Infiltration testing

• Exfiltration testing

Sanitary sewer gravity main testing

Low pressure air testing

1. Most common.

2. Quickest.

3. Most easily calibrated and field confirmed.

Sanitary sewer gravity main testing

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Infiltration testing

1. Allowed only when the water table gauges determine the groundwater level to be 2 feet or more above the highest pipe of the section being tested.

2. Made by measuring the quantity of water leaking into a section of pipeline.

Sanitary sewer gravity main testing

Exfiltration testing

1. Made by filling a section of pipeline with water and measuring the quantity of leakage.

2. Head of water at the beginning of the test shall be at least 2 feet above the highest pipe within the section being tested.

3. Allowable leakage (typical): 10 gallons per 24 hours per inch diameter per 1,000 feet. For 400 foot run of 8” PVC: 32 gallons.

Sanitary sewer gravity main testing

• Properly calibrated pressure gauge capable of reading 0.5 psi increments.

• Air compressor.Must be large enough to fill pipe in a timely fashion and, Provide make up air at the allowable air loss rate.

• Pipe plugs.Remotely inflated/deflated.Manual screw.

• Lateral plugs.

• Flashlights.

• Mirrors.

• Confined space gear.

• After 5 minutes, if pressure is maintained at 4 psi, the test is a success.

Sewer gravity main testing checklist

ASTM Standard F 1417 as a reference at 4.0 psi:

Typical maximum sanitary sewer main length in NJ is 400 feet.

Typical minimum sanitary sewer main diameter is 8 inches.

Sewer gravity main low air pressure testing

Pounds thrust force (F = pA) acting on test plugs:

Sewer gravity main low air pressure testing

Manual screw test plug Inflatable test plug

Sewer gravity main low air pressure testing

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Inspection Reports and Record Keeping

Four Acceptable AWWA Standard Disinfection Methods:

Tablet Method (water mains)• Utilizes calcium hypochlorite granules or tablets.• ≥ 0.2 mg/L free chlorine residual after 24 hours.

Continuous-Feed Method (water mains)• Utilizes sodium hypochlorite, calcium hypochlorite, or liquid chlorine.• Initial free chlorine residual of 25 mg/L. ≥ 10 mg/L free chlorine residual

after 24 hours.

Slug Method (water mains)• Utilizes sodium hypochlorite, calcium hypochlorite, or liquid chlorine.• 100 mg/L free chlorine residual for not less than 3 hours.

Spray Method (For large diameter water mains and storage tanks)• Utilizes sodium hypochlorite solution.• 200 mg/L free chlorine solution on all surfaces for not less than 30 min.

Disinfection of facilities Disinfection of facilities (cont’d)

Disinfection of facilities (cont’d)AWWA Standard C655-09 Dechlorination Methods:

Vacuum-Induced• Draws chemical into a device.• Device dechlorinates discharge water.

Passive• Tablets are placed in a device.• Device dechlorinates discharge water.

Drip-Style• Dechlorination solution added to discharge water.

Injection Pumps• Dechlorination solution added to discharge water.

Dechlorination of facilities

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Dechlorination Chemicals:

Sulfur Dioxide (gas)

Sodium Thiosulfate (powder)

Sodium Sulfite (powder or tablets)

Sodium Bisulfite (powder or liquid)

Sodium Metabisulfite (powder)

Calcium Thiosulfate (powder)

Ascorbic Acid (Vitamin C) (powder)

Sodium Ascorbate (powder)

Dechlorination of facilities (cont’d)

Pounds of chemicals to neutralize various residual chlorine concentrations in 100,000 gallons of water

Dechlorination of facilities (cont’d)

ResidualChlorine

Concentrationmg/l

SulfurDioxide(SO2)

SodiumBisulfite(NaHSO3)

SodiumSulfiteNa2SO3

SodiumThiosulfateNa2S2O35H2O

1 0.8 1.2 1.4 1.2

2 1.7 2.5 2.9 2.4

10 8.3 12.5   14.6   12.0  

50 41.7   62.6   73.0   60.0  

Dechlorination of facilities (cont’d)

Required before placing any drinking (potable) water facilities into service.

Free chlorine levels must be reduced to no more than normally expected background levels before sampling (i.e.: normal operating levels), or as close to zero mg/L as possible.

High chlorine residuals will mask a problem in a pipe or tank (i.e.: organics, dead animal, etc.).

Bac-t results measured in colonies per 100 mg/L of sampled water.

There are no fractions of colonies, only whole numbers (1, 2, 3, … 50).

Only one acceptable result: 0 colonies per 100 mg/L sample.

Bacteriological testing

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