405 - Pump Station Construction - Revision history

Clarkj25: /* RAIL PROJECTS */

2025-10-15T18:33:41Z

RAIL PROJECTS

Clarkj25 at 18:32, 15 October 2025

2025-10-15T18:32:54Z

Jhudson-fishbeck: /* Work on Existing Pump Stations */

2025-10-15T17:56:28Z

Work on Existing Pump Stations

Jhudson-fishbeck at 17:56, 15 October 2025

2025-10-15T17:56:03Z

Jhudson-fishbeck: /* Documentation */

2025-10-14T19:59:41Z

Documentation

Jhudson-fishbeck: /* INSPECTION & TESTING */

2025-10-14T19:58:40Z

INSPECTION & TESTING

Jhudson-fishbeck: /* Description of Equipment */

2025-10-14T19:55:40Z

Description of Equipment

Jhudson-fishbeck: /* MATERIALS */

2025-10-14T19:55:16Z

MATERIALS

Jhudson-fishbeck: /* General Overview */

2025-10-14T19:51:28Z

General Overview

Jhudson-fishbeck: /* Testing */

2025-10-14T19:49:51Z

Testing

← Older revision		Revision as of 18:33, 15 October 2025
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	[[Category:Section 405]]		[[Category:Section 405]]
		+	[[Category:New CM Format]]

← Older revision		Revision as of 18:32, 15 October 2025
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	<center><span STYLE="font: 40pt arial;">'''Pump Station Construction'''</span></center>		<center><span STYLE="font: 40pt arial;">'''Pump Station Construction'''</span></center>
−
−	~~<center>[http://mdotcf.state.mi.us/public/specbook/files/2012/405%20Pump%20Station%20Constr.pdf 2012 STANDARD SPECIFICATIONS FOR CONSTRUCTION - SECTION 405]</center>~~
−

	==[[#GENERAL DESCRIPTION\|GENERAL DESCRIPTION]]==		==[[#GENERAL DESCRIPTION\|GENERAL DESCRIPTION]]==

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 ==== Work on Existing Pump Stations ====
 Most frequent pump station work consists of maintaining existing pump stations. This work varies in nature but commonly includes the replacement of various components within the pump station. This could include the replacement of pumps, control panels, valves, and the wiring required to connect these various components. The plans and specifications will detail the components required to be replaced. Careful attention should be given to the size of the existing and new components to ensure reconfiguration of other components inside the pump station is not needed to facilitate replacement of the desired component.
 Construction begins with locating the component(s) to be replaced. Ideally, only the components getting replaced are taken out of service. Although, for certain work, the entire pump station must be shut down for replacement of a component. Once the component(s) is isolated from the system, the Contractor will work on disconnecting and removing the component(s). After the existing component is removed, the mounting bracket must be reviewed to ensure it works with the new component. If the existing mounting bracket does not work with the new component, a new mounting bracket must be installed. For mounting brackets requiring the use of epoxy, mortar, or other like compounds, sufficient time should be permitted for the product to cure before mounting the new component. The new component is then installed in the pump station on the mounting brackets and connected into the system. Some projects have special provisions detailing a testing and integration period to verify operation of the new component prior to final acceptance.

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 |+
 |-
-| [[File:Sound-earth-3.jpg|200px|thumb|center|Sound Earth]] || [[File:Class III Granular Material (Sand).jpg|200px|thumb|center|Class III Granular Material (Sand)]] || [[file:Class_II_Granular_Material.jpg|200px|thumb|center|Class II Granular Material.jpg]]
+| [[File:Sound-earth-3.jpg|200px|thumb|center|'''Sound Earth''']] || [[File:Class III Granular Material (Sand).jpg|200px|thumb|center|'''Class III Granular Material (Sand)''']] || [[file:Class_II_Granular_Material.jpg|200px|thumb|center|'''Class II Granular Material''']]
 |-
-|[[File:208-009.jpg|200px|thumb|center|34R Aggregate]]||[[File:208-011.jpg|200px|thumb|center|46G Aggregate]]||[[File:208-2-2-3.jpg|200px|thumb|center|21AA Material (dense graded)]]
+|[[File:208-009.jpg|200px|thumb|center|34R Aggregate]]||[[File:208-011.jpg|200px|thumb|center|'''46G Aggregate''']]||[[File:208-2-2-3.jpg|200px|thumb|center|'''21AA Material (dense graded)''']]
 |}
@@ Line 353: / Line 353: @@
 |+
 |-
-| [[File:405 (7).jpg|200px|thumb|center|Rubber Tired Crane]] || [[File:Excavator-3.jpg|200px|thumb|center|Excavator]] || [[File:Excavator-4.jpg|200px|thumb|center|Excavator with Plate Compactor Attachment (Ho-Pac)]]
+| [[File:405 (7).jpg|200px|thumb|center|'''Rubber Tired Crane''']] || [[File:Excavator-3.jpg|200px|thumb|center|'''Excavator''']] || [[File:Excavator-4.jpg|200px|thumb|center|'''Excavator with Plate Compactor Attachment (Ho-Pac)''']]
 |-
-| [[File:Bulldozer.jpg|200px|thumb|center|Bulldozer]] || [[File:Backhoe-2.jpg|200px|thumb|center|Rubber Tired Backhoe]] || [[File:401-017.jpg|200px|thumb|center|Portable Concrete Mixer]]
+| [[File:Bulldozer.jpg|200px|thumb|center|'''Bulldozer''']] || [[File:Backhoe-2.jpg|200px|thumb|center|'''Rubber Tired Backhoe''']] || [[File:401-017.jpg|200px|thumb|center|'''Portable Concrete Mixer''']]
 |-
-| [[File:401-018.jpg|200px|thumb|center|Plate Compactor]] || [[File:401-019.jpg|200px|thumb|center|Jumping Jack Compactor]] || [[File:Cutoff-saws.jpg|200px|thumb|center|Cutoff Saws]]
+| [[File:401-018.jpg|200px|thumb|center|'''Plate Compactor''']] || [[File:401-019.jpg|200px|thumb|center|'''Jumping Jack Compactor''']] || [[File:Cutoff-saws.jpg|200px|thumb|center|'''Cutoff Saws''']]
 |-
-| [[File:405 (16).jpg|200px|thumb|center|Trench Box]] || [[File:405 (17).jpg|200px|thumb|center|Stone/Sand Box]] || [[File:405 (18).jpg|200px|thumb|center|Sheet Piling (cold rolled)]]
+| [[File:405 (16).jpg|200px|thumb|center|'''Trench Box''']] || [[File:405 (17).jpg|200px|thumb|center|'''Stone/Sand Box''']] || [[File:405 (18).jpg|200px|thumb|center|'''Sheet Piling (cold rolled)''']]
 |-
-|[[File:405 (19).jpg|200px|thumb|center|Trench Boxes]]
+|[[File:405 (19).jpg|200px|thumb|center|'''Trench Boxes''']]
 |}

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 # Volume and tonnage of bedding and backfill material placed.
-Form 1900, Aggregate Inspection Daily Report, will need to be completed for every sublot of aggregate to track gradation acceptance.
+[https://mdotjboss.state.mi.us/webforms/GetDocument.htm?fileName=1900.pdf Form 1900, Aggregate Inspection Daily Report], will need to be completed for every sublot of aggregate to track gradation acceptance.
-Form 0582B, Moisture & Density Determination - Nuclear Method, is used to record density testing results.
+[https://mdotjboss.state.mi.us/webforms/GetDocument.htm?fileName=0582B.pdf Form 0582B, Moisture & Density Determination - Nuclear Method], is used to record density testing results.
-Delivery tickets must be verified for the source of material against the approved Materials Source List. Each ticket must include the required information. Refer to Subsection 109.01.B.6 of the Standard Specifications for Construction for the information required on each ticket.
+Delivery tickets must be verified for the source of material against the approved Materials Source List. Each ticket must include the required information. Refer to [https://mdotwiki.state.mi.us/images_construction/9/95/2020-Standard-Specifications-Construction.pdf#page=110 Subsection 109.01.B.6 of the Standard Specifications for Construction] for the information required on each ticket.
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 #* Non-Load Bearing Backfill: The maximum lift thickness permitted is 12 inches after compaction. Density needs to achieve a minimum of 95% compaction.
 #* Regardless of the intended load bearing capacity, density checks on backfill should occur on every lift.
-# Record the density testing results of the backfill material in accordance with the Density Testing and Inspection Manual using the field established maximum density for the material being tested. The minimum testing frequency is shown in Appendix K (backfill) of this manual. The testing frequencies listed are minimums that are satisfactory for acceptance. However, it is emphasized that project conditions normally require more frequent testing for proper density control.
+# Record the density testing results of the backfill material in accordance with the [https://www.michigan.gov/mdot/-/media/Project/Websites/MDOT/Business/Construction/Standard-Specifications-Construction/CFS-Manuals/Density-Testing-Inspection-Manual.pdf?rev=6ea61069b3b649e5bbd9362f000a4e0b&hash=44138356CA520616DF23E2E1D8E49AE0 Density Testing and Inspection Manual] using the field established maximum density for the material being tested. The minimum testing frequency is shown in Appendix K (backfill) of this manual. The testing frequencies listed are minimums that are satisfactory for acceptance. However, it is emphasized that project conditions normally require more frequent testing for proper density control.
 # Perform a moisture test on the aggregate material if payment is based on weight.
 # Ensure the appropriate test is used to determine the maximum density of the material:
 #* The One-Point Michigan Cone if natural or slag aggregates are used; or
-#* The Michigan Modified T-180 if crushed concrete is used as detailed in the Density Testing and Inspection Manual.
+#* The Michigan Modified T-180 if crushed concrete is used as detailed in the [https://www.michigan.gov/mdot/-/media/Project/Websites/MDOT/Business/Construction/Standard-Specifications-Construction/CFS-Manuals/Density-Testing-Inspection-Manual.pdf?rev=6ea61069b3b649e5bbd9362f000a4e0b&hash=44138356CA520616DF23E2E1D8E49AE0 Density Testing and Inspection Manual].
 #* All excavated material should be either removed from the site or stockpiled for testing to be approved for re-use onsite.
 # Verify the excavated area is secured according to contract documents if backfilling is not completed the same day as excavation.
 # Document any deviations from the original plans or specifications and ensure they are properly addressed before proceeding with further construction activities.
-Ensure construction is performed in accordance with plans, specifications, and shop drawings. VI and document all accepted portions of the constructed pump station. Fabrication imperfections or construction damage to pump stations must be repaired by the Contractor, as approved by the Engineer, in accordance with Section 712 of the Standard Specifications for Construction for all concrete or masonry components and at no additional cost to the contract.
+Ensure construction is performed in accordance with plans, specifications, and shop drawings. VI and document all accepted portions of the constructed pump station. Fabrication imperfections or construction damage to pump stations must be repaired by the Contractor, as approved by the Engineer, in accordance with [https://mdotwiki.state.mi.us/images_construction/9/95/2020-Standard-Specifications-Construction.pdf#page=485 Section 712 of the Standard Specifications for Construction] for all concrete or masonry components and at no additional cost to the contract.
-Natural aggregates must be provided in accordance with Section 902 of the Standard Specifications for Construction if the pump station is located near a waterway. Crushed concrete is not allowed for any work within 100 feet of a waterway. Check that materials being delivered to the project site are from the MDOT Prequalified Aggregate Supplier List. If a material is not being delivered from an MDOT prequalified pit, verify the material has documentation showing passing QA results. Salvaged existing material may be used after passing results are obtained from QA testing of an onsite stockpile.
+Natural aggregates must be provided in accordance with [https://mdotwiki.state.mi.us/images_construction/9/95/2020-Standard-Specifications-Construction.pdf#page=816 Section 902 of the Standard Specifications for Construction] if the pump station is located near a waterway. Crushed concrete is not allowed for any work within 100 feet of a waterway. Check that materials being delivered to the project site are from the MDOT Prequalified Aggregate Supplier List. If a material is not being delivered from an MDOT prequalified pit, verify the material has documentation showing passing QA results. Salvaged existing material may be used after passing results are obtained from QA testing of an onsite stockpile.
-All reinforcing steel must be epoxy-coated regardless of use. Refer to Section 905 of the Standard Specifications for Construction for additional steel reinforcement information.
+All reinforcing steel must be epoxy-coated regardless of use. Refer to [https://mdotwiki.state.mi.us/images_construction/9/95/2020-Standard-Specifications-Construction.pdf#page=855 Section 905 of the Standard Specifications for Construction] for additional steel reinforcement information.
 === Testing ===
-For evaluation of aggregate materials, use only certified aggregate sampling and testing technicians. Refer to the Procedures for Aggregate Inspection manual and project specifications for testing requirements and frequencies. The Engineer should track the approved testing of installed aggregate and coordinate with the respective testing lab to ensure the required number of aggregate tests for the project are being completed.
+For evaluation of aggregate materials, use only certified aggregate sampling and testing technicians. Refer to the [https://www.michigan.gov/mdot/-/media/Project/Websites/MDOT/Business/Construction/Standard-Specifications-Construction/CFS-Manuals/Procedures-Aggregate-Inspection.pdf?rev=e2f19aadca344460afca48b7b9ddb31e&hash=5D3CB25E2CD084FACCFD616004CCEB82 Procedures for Aggregate Inspection] manual and project specifications for testing requirements and frequencies. The Engineer should track the approved testing of installed aggregate and coordinate with the respective testing lab to ensure the required number of aggregate tests for the project are being completed.
 For every new source, new day, or suspected change in material, a moisture check must be completed. Obtaining moisture readings from a nuclear density gauge is only an approximation and is often used as a guide in the field. Official determination of moisture content will be made from a field sample stored in a plastic bag with the moisture content checked for payment using the oven dry method only if it is paid for by weight.
@@ Line 475: / Line 475: @@
 Perform density testing on compacted backfill. All backfill, regardless of material used, must be compacted to at least 95% of the maximum unit weight. Density tests need to be taken as close to the pipe as possible to obtain accurate information.
-To ensure excessive deformation of the pipe does not occur after backfilling and compaction, mandrel testing must be performed on at least 50% of all plastic pipe sizes. Refer to Division 4 of the Construction Manual for more information on mandrel testing of plastic pipe.
+To ensure excessive deformation of the pipe does not occur after backfilling and compaction, mandrel testing must be performed on at least 50% of all plastic pipe sizes. Refer to [https://mdotwiki.state.mi.us/construction/index.php?title=Division_4_Supplemental_Information Division 4 of the Construction Manual] for more information on mandrel testing of plastic pipe.
 Additional testing may be required for water tightness and pressure testing of the pump station piping. Refer to the special provisions for additional requirements.

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 === Description of Equipment ===
 Equipment used to construct pump stations varies greatly. This is primarily due to the varying size of pump stations from small, precast stations with only one pump to large stations which have to be constructed onsite and have numerous pumps.
-* For small pump stations, the excavator may dig the hole for the new pump station, place the precast components, lower the pumps in place, and backfill around the structure. Front end loaders, bulldozers, and compactors are also used in the backfilling process.
+* '''For small pump stations''', the excavator may dig the hole for the new pump station, place the precast components, lower the pumps in place, and backfill around the structure. Front end loaders, bulldozers, and compactors are also used in the backfilling process.
-* For large pump stations, an excavator is used to dig the hole where the new pump station will go. A crane is used to move forms into place to cast the new pump station onsite. Excavators, bulldozers, front end loaders, and compactors are used to backfill around the new pump station. The crane is also used to lower the pumps and various other components into the pump station.
+* '''For large pump stations''', an excavator is used to dig the hole where the new pump station will go. A crane is used to move forms into place to cast the new pump station onsite. Excavators, bulldozers, front end loaders, and compactors are used to backfill around the new pump station. The crane is also used to lower the pumps and various other components into the pump station.
 For areas requiring soil stabilization during construction, either an excavator or a crane is used to install components of a cofferdam. Both utilize special attachments to allow installation of sheeting for the cofferdam prior to excavation of earthen material where the proposed pump station will be installed.
 === Pictures of Equipment ===

@@ Line 50: / Line 50: @@
 ==[[#MATERIALS|MATERIALS]]==
-All materials governed by the Standard Specifications for Construction must meet acceptance requirements in the Materials Source Guide and be listed on the Contractor-provided Material Source Lists in the project files.
+All materials governed by the Standard Specifications for Construction must meet acceptance requirements in the [https://www.michigan.gov/mdot/Business/Construction/Materials-Source-Guide Materials Source Guide] and be listed on the Contractor-provided Material Source Lists in the project files.
 Pump stations include many materials, products, and equipment not addressed by the Standard Specifications for Construction. These products and materials require submittals be reviewed to ensure conformance with the design intent and performance characteristics necessary for proper operation of the pump station. Refer to the special provisions for these materials as well as required submittal and approval procedures. Submittals may be needed for items such as product/material details, material certifications, test results, and shop drawings.
@@ Line 57: / Line 57: @@
 ==== Piping ====
 ===== Exterior Piping =====
-The pipe material and class are noted on the plans. MDOT defines the pipe by class, which is based on the amount of cover over the pipe. Refer to Table 402-1 of the Standard Specifications for Construction for acceptable pipe in each class.
+The pipe material and class are noted on the plans. MDOT defines the pipe by class, which is based on the amount of cover over the pipe. Refer to [https://mdotwiki.state.mi.us/images_construction/9/95/2020-Standard-Specifications-Construction.pdf#page=222 Table 402-1 of the Standard Specifications for Construction] for acceptable pipe in each class.
 ===== Interior Piping =====
@@ Line 109: / Line 109: @@
 ==== Granular Material (Class II, IIA, IIAA, III, and IIIA) ====
-Granular backfill, often comprised of sand, is used to fill the space around existing or new features and the existing ground. Refer to Section 902 of the Standard Specifications for Construction for material requirements.
+Granular backfill, often comprised of sand, is used to fill the space around existing or new features and the existing ground. Refer to [https://mdotwiki.state.mi.us/images_construction/9/95/2020-Standard-Specifications-Construction.pdf#page=222 Section 902 of the Standard Specifications for Construction] for material requirements.
 ==== Aggregates ====
-Aggregates are often used as a base to support the pump station over existing ground. Depending on the project specifics, either open-graded or dense-graded aggregate is used. All aggregate must be in accordance with Subsection 902.05, Subsection 902.06, and Table 902-1 of the Standard Specifications for Construction.
+Aggregates are often used as a base to support the pump station over existing ground. Depending on the project specifics, either open-graded or dense-graded aggregate is used. All aggregate must be in accordance with [https://mdotwiki.state.mi.us/images_construction/9/95/2020-Standard-Specifications-Construction.pdf#page=821 Subsection 902.05], [https://mdotwiki.state.mi.us/images_construction/9/95/2020-Standard-Specifications-Construction.pdf#page=821 Subsection 902.06], and [https://mdotwiki.state.mi.us/images_construction/9/95/2020-Standard-Specifications-Construction.pdf#page=824 Table 902-1] of the Standard Specifications for Construction.
 ==== Pumps and Appurtenances ====
-All mechanical materials must be in accordance with Section 405 of the Standard Specifications for Construction, ASTM standards, the Hydraulic Institute, and as specified in project special provisions. Lubricants for pumps are to be recommended by the pump manufacturer.
+All mechanical materials must be in accordance with [https://mdotwiki.state.mi.us/images_construction/9/95/2020-Standard-Specifications-Construction.pdf#page=245 Section 405 of the Standard Specifications for Construction], ASTM standards, the Hydraulic Institute, and as specified in project special provisions. Lubricants for pumps are to be recommended by the pump manufacturer.
 Pumping equipment includes motors, discharge heads, baseplates and elbows, sole plates, pump column assemblies, bowl assemblies, supports, anchor bolts, and other items.
@@ Line 157: / Line 157: @@
 =====	Grounding and Bonding Equipment =====
-All ground and bonding equipment must be in accordance with Subsection 918.02.B of the Standard Specifications for Construction and the National Electrical Code (NEC). Typically, a minimum of three ground rods are required at 3/4-inch diameter and 10 feet long.
+All ground and bonding equipment must be in accordance with [https://mdotwiki.state.mi.us/images_construction/9/95/2020-Standard-Specifications-Construction.pdf#page=954 Subsection 918.02.B of the Standard Specifications for Constructio]n and the National Electrical Code (NEC). Typically, a minimum of three ground rods are required at 3/4-inch diameter and 10 feet long.
 ===== Hangers and Supports for Electrical Systems =====

@@ Line 45: / Line 45: @@
 === General Overview ===
-Pump station construction is extremely specialized work. Therefore, if a pump station is to be constructed, the plans and project special provisions are the primary resources detailing the work to be completed. It is important for the Inspector to know that a licensed electrical Contractor is required to perform all electrical work shown on the plans. The Contractor must guarantee the in-service operation of the mechanical and electrical equipment and related components for a period of six months following acceptance of the total contract, or as defined in the proposal, at which time all unexpired manufacturer’s equipment warranties will be assigned to MDOT. Refer to Division 8 of this manual for further information on pump station electrical requirements.
+Pump station construction is extremely specialized work. Therefore, if a pump station is to be constructed, the plans and project special provisions are the primary resources detailing the work to be completed. It is important for the Inspector to know that a licensed electrical Contractor is required to perform all electrical work shown on the plans. The Contractor must guarantee the in-service operation of the mechanical and electrical equipment and related components for a period of six months following acceptance of the total contract, or as defined in the proposal, at which time all unexpired manufacturer’s equipment warranties will be assigned to MDOT. Refer to [https://mdotwiki.state.mi.us/construction/index.php?title=Category:Division_8 Division 8] of this manual for further information on pump station electrical requirements.
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