SECTION 02082

MANHOLE COVERS AND FRAMES

TABLE OF CONTENTS

Item No Title Page No

PART 1 GENERAL............................................................................................................ 1

1.01 DESCRIPTION OF WORK .................................................................................. 1

1.02 SECTION INCLUDES .......................................................................................... 1

1.03 RELATED SECTIONS ......................................................................................... 1

1.04 REFERENCES..................................................................................................... 2

1.05 DEFINITIONS....................................................................................................... 3

1.06 SUBMITTALS....................................................................................................... 4

1.07 QUALITY CONTROL ........................................................................................... 4

1.08 HEALTH AND SAFETY CONSIDERATIONS...................................................... 4

1.09 DELIVERY, HANDLING AND STORAGE ........................................................... 5

PART 2 PRODUCTS ......................................................................................................... 6

2.01 GENERAL ............................................................................................................ 6

2.02 DESIGN AND MANUFACTURE .......................................................................... 6

2.03 PROTECTIVE COATING..................................................................................... 7

2.04 CLASSIFICATION................................................................................................ 7

2.05 APPEARANCE TEST .......................................................................................... 8

2.06 DIMENSIONAL MEASUREMENT ....................................................................... 8

2.07 WEIGHT MEASUREMENT.................................................................................. 9

2.08 LOADING TEST ................................................................................................... 9

2.09 SPECIAL REQUIREMENTS .............................................................................. 11

PART 3 EXECUTION ...................................................................................................... 12

3.01 INSPECTION ..................................................................................................... 12

3.02 INSTALLATION.................................................................................................. 12

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MANHOLE COVERS AND FRAMES

PART 1 GENERAL

1.01 DESCRIPTION OF WORK

A. This Section covers the furnishing and installation of cast iron/ductile iron
covers/gratings and frames for the utility structures, including but not limited to
manholes, handholes, joint boxes, draw pits, valve chambers and catch basins as
shown on the Contract Drawings.

B. The Contractor shall furnish all labor, materials, tools, equipment and other
incidentals as required to complete the Work in accordance with the Contract
requirements.

1.02 SECTION INCLUDES

A. Cast Iron Covers/Gratings and Frames

B. Ductile Iron Covers/Gratings and Frames

C. Design and Manufacture of Covers/Gratings and Frames

D. Classification of Covers/Gratings and Frames

E. Testing of Covers/Gratings and Frames

F. Installation of Covers/Gratings and Frames

1.03 RELATED SECTIONS

A. Section 01320 Construction Progress Documentation

B. Section 01330 Submittal Procedures

C. Section 01410 Regulatory Requirements

D. Section 01450 Quality Control

E. Section 01650 Product Delivery Requirements

F. Section 01660 Product Storage and Handling Requirements

G. Section 02085 Underground Piping Materials

H. Section 02510 Water Distribution

I. Section 02530 Sewerage System

J. Section 02630 Storm Drainage

K. Section 09910 Paints

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MANHOLE COVERS AND FRAMES

L. Section 16726 Installation of Telecommunication Facilities

1.04 REFERENCES

A. The referred codes and standards are intended to provide an acceptable level of
quality for materials, products and workmanship. In case of conflict between these
standards and the text of this Specification, the Specification text shall govern.

B. The latest revision of the referred codes and standards shall be used wherever
applicable. In case of conflict, the Contractor shall propose equipment, materials and
processes conforming to one group of codes and standards.

C. SASO Saudi Arabian Standards Organization

1. SASO 412 Methods of Test for Cast Iron Covers

2. SASO 413 Cast Iron Manhole Covers

3. SASO 821 Cast Iron Manhole and Handhole Covers and

Frames for Telephone Purposes

D. ASTM American Society for Testing and Materials

1. ASTM A48M Standard Specification for Gray Iron Castings

2. ASTM A536 Standard Specification for Ductile Iron Castings

E. BSI British Standards Institution

1. BS 3416 Black Bitumen Coating Solution for Cold Application

2. BS 4164 Coal Tar Based Hot Applied Coating Materials

3. BS 7903 Guide to Selection and Use of Gully Tops and

Manhole Covers for Installation Within the Highway

F. EN European Standard

1. BS EN 124 Gully Tops and Manhole Tops for Vehicular and

Pedestrian Areas - Design Requirements, Type
Testing, Marking, Quality Control

2. BS EN 1561 Founding - Grey Cast Irons

3. BS EN 1563 Founding - Spheroidal Graphite Cast Iron

G. NACE National Association of Corrosion Engineers

SSPC The Society for Protective Coatings

1. NACE No. 2 - SSPC SP10 Near- White Metal Blast Cleaning

2. NACE No. 3 - SSPC SP6 Commercial Blast Cleaning

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MANHOLE COVERS AND FRAMES

1.05 DEFINITIONS

A. area of waterway: The area of gully grating through which water can pass.

B. catch basin: A stormwater collection structure below ground designed to collect and
convey water into the storm sewer system.

C. clear area: The maximum unobstructed area through the frame (including the area
between the seats).

D. clear opening: The diameter of the largest circle that can be inscribed in the clear
area of the frame.

E. complete unit: The frame with the cover assembled on it.

F. cover: The movable part of a manhole top or a gully top which covers the manhole
or gully opening.

G. cushioning insert: Material in a frame, grating or cover used to provide a non-rock

seating.

H. ductile iron: Spheroidal or nodular graphite cast iron.

I. dust trap: A removable basket made from plastic reinforced with fiberglass or any
other suitable material, fixed in the frame for collecting dust passing through
ventilation opening.

J. frame: The fixed part of a gully top or manhole top which receives and supports a
grating or a cover.

K. grating: The movable part of a manhole top or a gully top, which permits the
passage of water through itself to the gully.

L. gully: An assembly to receive surface water for discharge into a drainage system.

M. gully top: That part of a gully, consisting of a frame and grating or cover and which
is placed on the gully pot at the place of installation.

N. gray iron: Flake graphite cast iron.

O. haunching: Lateral concrete backing of curbs and edgestones to restrain them in

position when loaded.

P. highway: Area that includes some or all of the following features: carriageway,
cycleway, footway, verge, hard shoulder, hard strip and central reservation.

Q. keyway: A hole in the top of the manhole cover suitable for the insertion of an
appropriate lifting key.

R. manhole: A chamber or access shaft to underground systems.

S. manhole top: That part of a manhole consisting of a frame and a cover or a grating.

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MANHOLE COVERS AND FRAMES

T. pedestrian areas: Area reserved for pedestrians and only occasionally open to
vehicular traffic for delivery, cleaning purposes or in emergency.

U. pedestrian streets: Area where vehicular traffic is prohibited during certain periods
(e.g. pedestrian areas during business hours and vehicular traffic outside these
hours).

V. seating: The surface on which the grating or the cover rests in the frame.

W. test load: Load applied to the cover or grating and frame when tested.

X. vent: An opening in the cover of a manhole top to provide ventilation.

1.06 SUBMITTALS

A. The Contractor shall submit to the Royal Commission, under the provisions of
SECTION 01330, the following items for review and approval before commencing
Work:

1. Certificate of compliance stating that the covers/gratings and frames and all
materials used in their construction conform to all requirements of this
Specification.

2. Certificate of testing including test data to show that all tests specified have
been performed and all requirements have been met.

3. Manufacturer’s recommended specification and instructions for transporting,

handling, loading, unloading and storage of the covers/gratings and frames.

4. Catalog data showing illustrations and schedule of parts, material and weights
of the covers/gratings and frames.

5. Shop Drawings showing the principal dimensions, construction details, and

materials.

1.07 QUALITY CONTROL

A. The Contractor shall be responsible for the quality of work and shall develop and
propose programs and methods of construction and testing such as to achieve the
specified quality to the approval of the Royal Commission in accordance with
SECTION 01450.

1.08 HEALTH AND SAFETY CONSIDERATIONS

A. All works undertaken in relation to this Specification are to be completed in full

accordance with the respective health and safety requirements established by the
following:

1. Kingdom of Saudi Arabia

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MANHOLE COVERS AND FRAMES

a) Legislation, Regulation, Standards and Codes.

2. Royal Commission Regulations

a) Standards, Contractual Conditions, and Health and Safety Systems.

3. Contractor

a) Health and Safety Standards and Systems as accepted by the Royal

Commission.

B. In the absence of any of the above, best accepted industry practice shall be
employed throughout.

1.09 DELIVERY, HANDLING AND STORAGE

A. The Contractor shall deliver, handle and store equipment and material units in
accordance with SECTIONS 01650 and 01660, as well as the following
requirements:

1. Packaging shall be provided as required for shipment of covers/gratings and

frames to the installation site.

2. All units shall be inspected at time of delivery for shipment damage and for
compliance with the Specifications.

3. Any product found to be damaged or not in accordance with the Specifications

shall immediately be repaired or removed from site and replaced at no
additional cost to the Royal Commission, without impairing the project’s
performance or schedule.

4. Repairs shall not be undertaken before the Royal Commission’s review of the
Contractor’s proposed action.

5. All units shall be stored and handled at the construction site in a manner to
prevent damage and deterioration.

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PART 2 PRODUCTS

2.01 GENERAL

A. All goods and products covered by these Specifications shall be procured, when
available, from an in Kingdom manufacturer. Procurement of all goods and products
manufactured out-of-Kingdom must be approved by the Royal Commission.

B. The Royal Commission shall, at all times, have access to all places where materials
are being produced or fabricated or where tests are being conducted, and shall be
accorded full facilities for inspection and observation of tests.

C. Proprietary products considered by the Contractor to meet this Specification shall be

approved by the Royal Commission, based on the Contractor's report and
recommendation prior to incorporation into the permanent works.

2.02 DESIGN AND MANUFACTURE

A. General

1. All castings shall be true to pattern in form, dimensions and thickness; shall be
free from impurities, pits, porosity, cracks, protrusions, blowholes, and other
machine operation defects which would impair the service value of the
castings. Castings shall be matched sets in appearance and size as shown on
the Contract Drawings.

B. Covers/gratings and frames shall be gray cast iron or ductile iron castings, as follows:

1. Gray cast iron shall conform to or exceed the requirement of either

ASTM A48M Class 30 or BS EN 1561 Grade EN-GJL-200.

2. Ductile iron shall conform to or exceed the requirements of either ASTM A536
Grade 80-55-06 or BS EN 1563 Grade EN-GJS-600-3.

C. Seating

1. The manufacture of covers/gratings and frames shall be such as to ensure the

compatibility of their seatings.

2. The upper surface of the cover shall be flush with that of the upper frame. The
bearing surfaces of frames and covers shall be machined to ensure that the
covers will seat firmly in the frame without rocking or rattling.

3. For square and rectangular manhole covers, in lieu of machining, a rubber

gasket is permitted.

D. Openable Covers

1. The covers/gratings shall be secured within their frames to meet the

serviceability requirements in such a way as to allow the opening of covers or
gratings by means of usual tools.

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MANHOLE COVERS AND FRAMES

E. Fixed Covers

1. In case of fixed covers, the means of fixing the cover to the frame shall be
made of stainless steel, or coated with suitable coating resistant to rust.

F. Cover Top Surface

1. Shall be plane or have non-skid pattern.

2. Shall have cast inscription of the utility name both in English and Arabic as
shown on the Contract Drawings.

G. Covers with Openings for Ventilation

1. The total area of the ventilation openings shall not be less than 5% of the area
of the clear manhole opening.

2. The diameter/width of one ventilation opening shall not be more than 40 mm

and its length shall not exceed 125 mm.

3. Covers shall be provided with dust traps.

2.03 PROTECTIVE COATING

A. The castings to be coated shall be clean and dry. Rust, grease, or any adhesive or
suspended materials on the surfaces shall be removed prior to the application of
coating.

B. Unless otherwise specified, the castings shall have priming coat of

Zinc Silicate 100 micron in accordance with NACE No. 3 - SSPC SP6 or
NACE No. 2 - SSPC SP10. Two finish coats shall be of coal tar epoxy, each coat
being 100 microns thick.

C. The coating shall be smooth, free of bare patches or lack of adhesion and capable of
sustaining the prevailing local weather conditions.

2.04 CLASSIFICATION

A. The class of covers/grating and frame shall be as specified on the Contract

Drawings.

B. Covers/gratings and frames shall comply with the common classification system of
BS EN 124, which applies to all situations, road and off road and all materials and is
based on the place of installation of the units, as shown in Table 2A.

C. Where there is any doubt regarding the selection of an appropriate class, the
stronger class shall be selected.

D. The covers/gratings and frames shall be classified as Heavy Duty, if they meet the
requirements of the Class D400 of the Table 2A.

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MANHOLE COVERS AND FRAMES

E. The covers/gratings and frames shall be classified as Medium Duty, if they meet the
requirements of the Class B125 of the Table 2A.

F. The covers/gratings and frames shall be classified as Light Duty, if they meet the
requirements of the Class A15 of the Table 2A.

TABLE 2A: MANHOLE COVER/GRATING CLASSIFICATION

Test Loads
Class Place of Installation
(kN)
Areas which can be used by pedestrians and pedal
A15 15
cyclist.
Footways, pedestrian areas and comparable areas, car
B125 125
parks or car parking decks.
For gully tops installed in the kerbside channels of
roads, which, when measured from the kerb edge,
C250 250
extend a maximum of 0.5 m into the carriageway and a
maximum of 0.2 m into the footway.

Carriageways of roads (including pedestrian streets),

D400 400 hard shoulders and parking areas for all types of road
vehicles.

2.05 APPEARANCE TEST

A. The covers/gratings and frames shall be inspected with naked eye to assure absence
of any visible defects such as fractures, cracks, bending, pits, protrusions and
blowholes.

B. The coating layer shall be examined with naked eye, to assure that the
covers/gratings and frames are completely coated and that the coating layers are
smooth and completely adherent to the surface, ensuring that there is no sand under
the coating layer.

C. The cover shall be fixed in its relevant frame. They shall be tight with plane surfaces,
and the cover shall not shake when placed in its position.

2.06 DIMENSIONAL MEASUREMENT

A. The cover/grating diameter/side shall be measured at its upper surface in 4 positions

distributed on the circumference and the mean value taken.

B. The frame diameter/side shall be measured at the inside of the upper edge in
4 positions distributed on the circumference and the mean value taken.

C. The difference between the diameter/side of the cover/grating and its frame, as
measured in pars. 2.06 A and B above shall be calculated.

D. The clear opening diameter/side shall be measured in 4 positions, distributed on the

circumference and the mean value taken.

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MANHOLE COVERS AND FRAMES

E. The depth of the frame flange (the distance between the upper edge of the frame and
the surface of the flange on which the cover is supported) shall be measured in
4 positions, distributed on the circumference and the mean value taken.

2.07 WEIGHT MEASUREMENT

A. The complete unit shall be weighed to the nearest 0.5 kg.

2.08 LOADING TEST

A. General

1. All covers/gratings and frames shall be tested as complete units in their

condition of service except for recessed covers delivered unfilled, which shall
be load tested without filling.

2. Compliance with the loading requirements for the appropriate class shall be
determined by loading test.

3. Testing of the covers/gratings and frames shall be performed in accordance

with the procedure described in BS EN 124.

4. All tests shall be performed by the manufacturer.

B. Objective of the Test

1. To measure the permanent set of the cover or grating on the application of

2
/3 of the test load.

2. To detect any crack or fracture, if formed in the test unit on the application of
the full test load.

C. Test Loads

1. For covers/gratings and frames with clear opening (CO) equal to or greater
than 250 mm, the test loads shall be as shown in Table 2A.

2. Where clear opening (CO) is less than 250 mm, the test loads shall be as
shown in Table 2A, multiplied by CO/250.

D. Testing Machine

1. The testing machine, preferably a hydraulic test press, shall be capable of

applying a load at least 25% greater than the respective test load.

2. The dimensions of the bed of the testing machine shall be greater than the
bearing area of the unit to be tested.

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MANHOLE COVERS AND FRAMES

E. Test Blocks

1. The dimensions and shapes of test blocks shall be as shown in Table 2B.

TABLE 2B: DIMENSIONS AND SHAPES OF TEST BLOCKS

Clear Opening Dimensions of

(CO) Shape of Cover/Grating the Test Blocks
mm (mm)
Circular, Triangular or Rectangular
300 < CO ” 1000 250 ĭ
(largest dimension of rectangle > 300mm)
Rectangular (largest dimension of
200 ” CO ” 300 250 x 150
rectangle > 300mm)
Circular, Triangular or Rectangular
200 ” CO ” 300 150 ĭ
(largest dimension of rectangle ” 300mm)
Rectangular (largest dimension of
CO < 200 250 x 75
rectangle > 300mm)
Circular, Triangular or Rectangular
CO < 200 75 ĭ
(largest dimension of rectangle ” 300mm)

F. Preparation for the Test

1. The test block shall be placed on the unit with its vertical axis perpendicular to
the surface and coincidental with the geometric center of the cover or grating.
The cover or grating shall rest normally in the frame.

2. The test load shall be uniformly distributed over the whole surface of the test
block and any irregularities compensated for by means of an appropriate
intermediate layer of soft wood, fiber board, felt or similar material positioned
between the cover or grating and the test block. The dimensions of this
intermediate layer shall not be larger than those of the test block. A similar
intermediate layer shall also be positioned between the bed of the testing
machine and the test unit.

G. Application of Test Load.

1. The test load shall be gradually applied at a rate of 1 to 5 kN/s, up to 2/3 of the
test load; the load on the test unit shall be released then.

2. This process of loading and unloading shall be carried out 5 times and then
after unloading for the fifth time, the permanent set shall be measured at the
geometric center.

3. Immediately after measuring the permanent set, the load shall again be
increased at the same rate till it reaches the maximum value. Test load shall
be sustained on the test unit for a minimum period of 30 seconds.

H. Acceptance Criteria

1. The test units shall not exhibit any crack, fracture or any other defect in the

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MANHOLE COVERS AND FRAMES

course of the test.

2. Permanent set for Classes A15 and B125 shall not exceed CO/100 and that
for Classes C250 and D400 shall not exceed CO/500.

2.09 SPECIAL REQUIREMENTS

A. Sealed or locked covers and frames sizes and details shall be in accordance with the
Contract Drawings.

1. Sealing shall be of either single or double pattern and the minimum depth of
penetration of the cover sealing flanges into the frame shall be 10 mm. The
seal shall be continuous to serve its purpose effectively.

2. Locking shall not nullify the seal. Where locking devices can be rendered
ineffective by corrosion, they shall be suitably protected. If the locking device
utilizes a bolt connection, this shall be stainless steel.

B. Recessed covers shall receive in-fill material specified by the manufacturer to meet
the required design loads.

C. Glass reinforced plastic (GRP) sub-frames and seal plates shall be specifically
designed to be compatible for use with the cover-manufacturer's products and used
only per special request on the design drawings.

D. Inscriptions, cover surfaces (protruding skid preventing pattern), lifting and locking
devices and provision for gas detection on covers shall be as shown on Contract
Drawings.

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MANHOLE COVERS AND FRAMES

PART 3 EXECUTION

3.01 INSPECTION

A. The Contractor shall inspect the cover/grating and frame prior to installation to verify
that they are in conformance with this Specification.

3.02 INSTALLATION

A. The Contractor shall install the cover and frame strictly in accordance with the
manufacturers instructions and recommendations and the details shown on the
Contract Drawings.

B. The Contractor shall prevent distortion of the frames during fixing and shall replace
any distorted cover/grating or frame.

C. Covers/gratings and frames shall be installed in such a manner as to prevent

infiltration of the surface or ground water between the frame and the manhole
section.

D. Covers/gratings and frames shall be set to the true locations, planes and grades and
shall not be subject to traffic loads until the elapse of an adequate curing time for the
bedding and haunching material.

E. All covers shall be bedded and leveled to prevent rocking and lateral movement of
the frame under the influence of the traffic or other imposed loads.

F. In the paved areas and the road shoulders, the top of the covers shall be flush with
the finished surface. In unpaved areas, the top of the covers shall be 100 mm above
the finished grade.

END OF SECTION

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