2017-04 LAWA NCOSC Specs FINAL … · Section 03305 Electrical and Instrumentation Duct Encasement...

North Central Outfall Sewer Connection Project

ATTACHMENT 7:

Technical Specifications

Bid Set April 2017

Table of Contents TOC-1

NORTH CENTRAL OUTFALL SEWER CONNECTION LOS ANGELES INTERNATIONAL AIRPORT Los Angeles World Airports

TABLE OF CONTENTS FOR CONSTRUCTION OF

NORTH CENTRAL OUTFALL SEWER

CONNECTION PROJECT No. 20160027

TECHNICAL SPECIFICATIONS

DIVISION 1 - GENERAL REQUIREMENTS

Section 01171 Low Voltage Electric Motors Section 01445 Pipeline Testing and Cleaning Section 01480 Tightness Testing of Liquid Retaining Structures Section 01612 Seismic Design Criteria Section 01614 Wind Design Criterial

DIVISION 2 - SITEWORK

Section 02050 Demolition Section 02200 Earthwork Section 02221 Trenching, Backfilling and Compaction Section 02230 Granular Fill Materials Section 02311 Excavation Support and Protection Section 02313 Controlled Low-Strength Material Section 02500 Asphaltic Concrete Pavement Section 02605 Precast Concrete Manholes and Structures Section 02616 Ductile Iron Pipe and Fittings Section 02627 Fiberglass Gravity Sewer Pipe Section 02765 Plastic Lining for Precast Concrete Section 02766 Plastic Lining for Cast-in-Place Concrete

DIVISION 3 - CONCRETE

Section 03100 Concrete Formwork Section 03200 Concrete Reinforcement Section 03250 Concrete Joints and Joint Accessories Section 03300 Cast-In-Place Concrete Section 03305 Electrical and Instrumentation Duct Encasement Concrete Section 03350 Concrete Finishes Section 03360 Shotcrete Section 03600 Grout Section 03740 Modifications to Existing Concrete

DIVISION 5 - METALS

Section 05500 Miscellaneous Metals

Bid Set April 2017

Table of Contents TOC-2


DIVISION 7 – THERMAL AND MOISTURE PROTECTION

Section 07110 Dampproofing Section 07920 Joint Sealants

DIVISION 9 - FINISHES

Section 09901 Surface Preparation and Shop Painting Section 09902 Field Painting

DIVISION 11 - EQUIPMENT

Section 11306 Submersible Solids Handling Pumps

DIVISION 13 - SPECIAL CONSTRUCTION

Section 13120 Pre-engineered Canopy Section 13300 Instrumentation and Controls - General Provisions Section 13302 Instrumentation and Controls - Testing Section 13303 Instrumentation and Controls – Training Section 13305 Instrumentation and Controls – Control Descriptions Section 13306 Instrumentation and Controls – Application Engineering Services Section 13311 PLC Hardware and Software Section 13330 Instrumentation and Controls – Control Panels and Panel Mounted

Equipment Section 13335 Instrumentation and Controls – Control Panel Uninterruptible Power

Supply (Single Phase) Section 13340 Instrumentation and Controls – Instruments

DIVISION 15 - MECHANICAL

Section 15050 Piping – General Requirements Section 15066 Stainless Steel Pipe and Fittings Section 15072 Ductile Iron Pipe and Fittings Section 15100 Valves Section 15120 Piping Specialties Section 15140 Pipe Hangers and Supports

DIVISION 16 - ELECTRICAL

Section 16020 Electrical

PLANS ..............................................................................................SEPARATE DOCUMENTS

Title: NORTH CENTRAL OUTFALL SEWER

CONNECTION PROJECT NO. 20160027

Drawing No. 20160027, SHEETS NO. G-1 THROUGH REF-5, 40 sheets

Bid Set April 2017

Low Voltage Electric Motors 01171-1


SECTION 01171

LOW VOLTAGE ELECTRIC MOTORS

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Motors, up to 200 Hp, furnished under other Sections, shall be in conformance with the

requirements listed in this Section unless otherwise noted. 1.2 RELATED WORK

A. Electric motor field testing is included in Section 16020.

1.3 SUBMITTALS

A. Submittal of motor data for acceptance shall include complete nameplate data and test characteristics in accordance with NEMA Standard MG1-12.54 "Report of Test Form for Routine Tests on Induction Motors" and, in addition, the following for motors typical of the units furnished:

1. Efficiency at 1/2, 3/4 and full load

2. Power factor at 1/2, 3/4 and full load

3. Motor outline, dimensions and weight

4. Descriptive bulletins, including:

A. Rated horsepower, voltage, full load current, kVA code, and locked rotor current at

rated voltage

B. Frequency and number of phases

C. Motor connection diagram

D. Service factor, design duty, insulation class, and temperature rise by resistance

E. Ambient temperature and altitude ratings

F. NEMA design class

G. Nominal and full load speed

5. Bearing design data

6. Special features (i.e., space heaters, temperature detectors, etc.)

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7. Power factor correction capacitor rating and type.

8. Enclosure type and finish.

9. Certified factory test reports in accordance with NEMA Standards MG1-12.54, Report of Test Form for Routine Tests on Induction Motors.

1.4 REFERENCE STANDARDS

A. Institute of Electrical and Electronics Engineers (IEEE)

1. IEEE 112, Standard Test Procedure for Polyphase Induction Motors and

Generators.

2. IEEE 114, Standard Test Procedures for Single-Phase Induction Motors.

B. National Electrical Manufacturers Association (NEMA)

1. NEMA MG1, Motors and Generators.

C. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.

1.5 QUALITY ASSURANCE

A. Routine tests shall be performed on representative motors, and shall include the

information described on NEMA MG1-12.54 "Report of Test Form for Routine Tests on Induction Motors". Efficiency shall be determined in accordance with IEEE Publication No. 112, Method B. Power factor shall be measured on representative motors.

1.6 SYSTEM DESCRIPTION

A. Motors specified herein are three phase, squirrel cage induction type for 1/2 Hp and

above; single phase for less than 1/2 Hp; or DC motors.

PART 2 PRODUCTS 2.1 RATING

A. Each motor shall develop ample torque for its required service throughout its

acceleration range at a voltage 10 percent below nameplate rating. Where shown on the Electrical Drawings to be operated on a reduced voltage starter, the motor shall develop ample torque under the conditions imposed by the reduced voltage starting method.

B. The motor shall not be required to deliver more than its rated nameplate horsepower, at

unity (1.0) service factor, under any condition of mechanical or hydraulic loading.

Bid Set April 2017



C. All motors shall be continuous time rated suitable for operation in a 50 degrees C ambient and altitude less than 1,000 meters unless noted otherwise.

D. Specific motor data such as Hp, rpm, enclosure type, etc, is specified under the detailed

specification for the equipment with which the motor is supplied. 2.2 ENCLOSURE TYPES

A. Motors specified herein will conform to one of the following standard enclosure designs:

1. Open Drip Proof

2. Totally Enclosed Fan Cooled (TEFC)

3. Totally Enclosed Non-Ventilated (TENV)

4. Explosion Proof

5. Severe Duty

B. Windings shall be copper.

C. Provide ground lug inside the motor lead conduit.

D. Provide lifting eye on each motor weighing more than 50 pounds. Each motor shall be

suitable for six starts per hour (5 minutes on and 5 minutes off, continuously) when powering the specific driven equipment required for this project.

E. Each motor shall have an overall sound power level at no load not greater than given in

NEMA MG1-12.49.

F. Motors which have special operating characteristics such as multi-speed, high torque/high slip, short time intermittent ratings shall be name plated to show how these characteristics differ from standard design.

2.3 NAMEPLATES

A. The motor manufacturer's nameplates shall be engraved or embossed on stainless

steel and fastened to the motor frame with stainless steel screws or drive pins. Nameplates shall indicate clearly all of the items of information enumerated in NEMA Standard MGI-10.38 or MGI-20.60, as applicable.

2.4 CONDENSATION HEATERS

A. Condensation heaters, where specified under the detailed mechanical specifications shall

be of the cartridge or flexible wrap around type installed within the motor enclosure adjacent to core iron. Heaters shall be rated for 120 Volt, single phase with wattage as required. The heater wattage and voltage shall be embossed on the motor nameplate. Power leads for heaters shall be brought out at the motor lead junction box.

2.5 WINDING TEMPERATURE DETECTORS

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A. Winding temperature detectors, where specified under the detailed mechanical specifications for individual equipment shall be a factory installed, embedded, bi-metallic switch type with leads terminating in the main conduit box. This device shall protect the motor against damage from overheating caused by single phasing, overload, high ambient temperature, abnormal voltage, locked rotor, frequent starts or ventilation failure. The switch shall have normally closed contacts. Not less than three detectors shall be furnished with each motor.

B. Motors connected to variable frequency drives shall be equipped with winding

temperature detectors. 2.6 SINGLE PHASE MOTORS

A. Unless otherwise specified, motors smaller than 1/2 Hp shall be single phase, capacitor

start. Small fan motors may be split-phase or shaded pole type if such are standard for the equipment. Wound rotor or commutator type single-phase motors are not acceptable unless their specific characteristics are necessary for the application.

B. Motors shall be rated for operation at 115 Volts, single phase, 60 Hz.

C. Locked rotor current shall not be greater than specified in NEMA Standard MGI-12.32,

Design "N".

D. Motors shall be totally-enclosed in conformance with NEMA Standard MGI-10.35. Small fan motors may be open type if suitably protected from moisture, dripping water and lint accumulation.

E. Motors shall be provided with sealed ball bearings lubricated for 10 years normal use.

2.7 THREE PHASE MOTORS-FRAMES 143T THROUGH 449T

A. General

1. Unless otherwise specified, motors 1/2 Hp and larger shall be 3 Phase, squirrel

cage induction type.

2. All motors 3/4 Hp and larger shall be a NEMA frame 143T or larger. 1/2 Hp motors and 3/4 Hp motors rated 1800 and 3600 rpm, shall be a 56 frame. Motors shall be designed and connected for operation on a 480 Volt, 3 Phase, 60 Hz alternating current system. Dual voltage (230/460) rated motors are acceptable.

3. Unless otherwise required by the load, all motors shall be NEMA Design B, normal

starting torque. Locked rotor kVA/Hp shall not exceed Code Letter G as described in NEMA Standard MG1-10.37 for motors 20 Hp and larger.

4. Motors shall be as manufactured by Reliance Electric, U.S. Electrical Motors,

Division of Emerson Electric Co., or equal.

B. Bearings

Bid Set April 2017



1. Anti-friction motor bearings shall be designed to be regreasable and initially shall be filled with grease suitable to ambient temperature of 50 degrees C. Bearings shall be AFBMA Types BC or RN, heavy duty, or shall otherwise be shown to be suitable for the intended application in terms of B-10 rating life, Class M3 or better.

2. All grease lubricated bearings, except those specified to be factory sealed and

lubricated, shall be fitted with easily accessible grease supply, flush, drain and relief fittings. Extension tubes shall be used when necessary. Grease supply fittings shall be standard hydraulic type by the Alemite Division of the Stewart-Warner Corporation.

C. Insulation

1. Insulation systems shall be Class F, operated at Class B temperature rise and shall be

manufacturer's premium grade, resistant to attack by moisture, acids, alkalies and mechanical or thermal shock.

2. Motors shall have vacuum/pressure impregnated epoxy insulation for moisture

resistance.

D. Enclosures

1. Motors shall have a steel or cast iron frame and a cast iron or stamped steel conduit box, as specified below. Conduit box shall be split from top to bottom and shall be capable of being rotated to four positions. Synthetic rubber-like gaskets shall be provided between the frame and the conduit box and between the conduit box and its cover. Motor leads shall be sealed with a non-wicking, non-hygroscopic insulating material. A frame mounted pad with drilled and tapped hole, not less than 1/4-in diameter, shall be provided inside the conduit box for motor frame grounding. Provide a separate conduit box for space heater and/or winding temperature detector leads for all motors 100 HP and larger.

a. Totally enclosed fan cooled: TEFC motors shall have a steel or cast iron frame,

cast iron end brackets, cast iron conduit box, 1.15 service factor at rated temperature, tapped drain holes (corrosion resistant plugs for frames 286T and smaller and automatic breather/drain devices for frames 324T and larger) and upgraded insulation by additional dips and bakes to increase moisture resistance.

b. Totally enclosed non-ventilated: TENV motors shall include the same rating

and accessories as specified for TEFC motors.

c. Severe duty: Motors shall be of the corrosion resistant type conforming to motors designated by the manufacturer as "Corro-Duty", "Mill and Chemical", "Custom Severe Duty", or similar quality designation. Severe duty motors shall have a cast iron frame, cast iron end brackets, cast iron conduit box and 1.15 service factor at [40] degrees C and tapped drain holes (corrosion resistant plug for frames 286T and smaller and automatic breather/drain devices for frames 324T and larger).

Bid Set April 2017



E. Motor Efficiencies

1. Three phase motors rated 1 Hp and larger shall be of the premium efficiency type. Unless noted otherwise, motors shall have a NEMA Nominal Efficiency not less than the values indicated in Table 01171-1. Where Design E motors are specifically called for in the detailed technical specifications, motors shall have NEMA Nominal Efficiency and Minimum Efficiency not less than the values indicated in Table 01171-2. Efficiency values shall be based on tests performed in accordance with IEEE Publication No. 112, Method B. Motors with horsepower or rpms not listed shall conform to comparable standards of construction and materials as those for listed motors.

2. Special application motors (e.g., DC motors), intermittent duty motors (e.g., value

actuators, elevators, cranes), submersible, or explosion proof motors, shall not be required to meet these efficiencies unless specifically called for in the detailed specifications. Provide manufacturer’s standard motors in these cases.

PART 3 EXECUTION

3.1 GENERAL

A. Install all motors in accordance with the manufacturer’s printed recommendations and

as required under the specific specification sections for the driven equipment.

B. Electrical field testing shall be in accordance with Section 16000.

Table 01171-1 Full Load Efficiencies, Standard Open Motors

OPEN MOTORS

HP

3600 RPM 1800 RPM 1200 RPM 900 RPM

Nom. Effic

Min. Effic.

Nom. Effic

Min. Effic.

Nom. Effic

Min. Effic.

Nom. Effic

Min. Effic.

1.0 80.0 ---- 82.5 80.0 80.0 74.0 72.0 68.0

1.5 82.5 77.0 84.0 80.0 84.0 80.0 75.5 72.0

2.0 84.0 80.0 84.0 80.0 86.5 81.5 85.5 82.5

3.0 84.0 80.0 86.5 84.0 86.5 82.5 86.5 84.0

5.0 85.5 82.5 87.5 84.0 88.5 84.0 87.5 85.5

7.5 87.5 82.5 88.5 86.5 89.5 86.5 88.5 86.5

10.0 88.5 85.5 89.5 86.5 90.2 88.5 89.5 87.5

15.0 89.5 87.5 91.0 88.5 91.0 87.5 89.5 87.5

20.0 90.2 88.5 91.0 89.5 91.0 88.5 90.2 88.5

25.0 91.0 89.5 92.4 90.2 91.7 89.5 90.2 88.5

30.0 91.0 89.5 93.0 90.2 92.4 90.2 91.1 89.5

40.0 92.4 90.2 93.0 91.0 93.0 90.2 90.2 88.5

50.0 92.4 90.2 93.0 91.0 93.0 90.2 91.7 90.2

60.0 93.0 91.7 93.6 91.7 93.6 91.0 92.4 91.0

75.0 93.0 91.7 94.1 92.4 93.6 91.7 93.6 92.4

Bid Set April 2017



Table 01171-1 (continued) Full Load Efficiencies, Standard Open Motors

OPEN MOTORS

HP

3600 RPM 1800 RPM 1200 RPM 900 RPM

Nom. Effic

Min. Effic.

Nom. Effic

Min. Effic.

Nom. Effic

Min. Effic.

Nom. Effic

Min. Effic.

100.0 93.6 91.7 94.1 92.4 94.1 92.4 93.6 92.4

125.0 96.6 93.6 94.5 92.4 94.1 92.4 93.6 92.4

150.0 93.6 92.4 95.0 93.0 94.5 92.4 93.6 92.4

200.0 94.5 92.4 95.0 93.0 94.5 93.0 93.6 92.4

Table 01171-2 Full Load Efficiencies, Standard Enclosed Motors

ENCLOSED MOTORS

HP

3600 RPM 1800 RPM 1200 RPM 900 RPM

Nom. Effic

Min. Effic.

Nom. Effic

Min. Effic.

Nom. Effic

Min. Effic.

Nom. Effic

Min. Effic.

1.0 80.0 --- 82.5 77.0 81.5 72.0 72.0 68.0

1.5 84.0 75.5 84.0 78.5 85.5 80.0 75.5 72.0

2.0 85.5 78.5 84.0 80.0 86.5 80.0 82.5 80.0

3.0 86.5 80.0 88.5 81.5 88.5 81.5 81.5 78.5

5.0 87.5 82.5 88.5 82.5 88.5 82.5 84.0 81.5

7.5 88.5 82.5 91.0 85.5 89.5 85.5 85.5 82.5

10.0 89.5 85.5 91.0 85.5 89.5 85.5 87.5 85.5

15.0 90.2 85.5 91.0 86.5 90.2 87.5 88.5 86.5

20.0 90.2 86.5 91.7 88.5 91.0 87.5 89.5 87.5

25.0 91.0 87.5 92.4 89.5 91.7 88.5 89.5 87.5

30.0 91.0 87.5 93.0 89.5 92.4 89.5 90.2 88.5

40.0 91.7 88.5 93.0 90.2 93.0 90.2 90.2 88.5

50.0 92.4 88.5 93.6 91.0 93.6 90.2 91.0 89.5

60.0 94.1 90.2 94.1 91.7 93.6 90.2 91.7 90.2

75.0 94.1 91.0 94.5 91.7 94.7 91.7 93.0 91.7

100.0 94.1 91.7 95.0 92.4 94.7 91.7 93.0 91.7

125.0 94.5 91.7 95.0 92.4 94.7 91.7 93.6 92.4

150.0 94.5 91.7 95.0 93.0 95.0 93.0 93.6 92.4

200.0 95.0 93.0 95.0 93.6 95.0 93.0 94.1 93.0

Nom. = Nominal Min. = Minimum Effic. = Efficiency

END OF SECTION


This Page Intentionally Left Blank


Bid Set Low Voltage Electric Motors April 2017 01171-8

Bid Set April 2017

Pipeline Testing and Cleaning 01445 - 1


SECTION 01445 PIPELINE

TESTING AND CLEANING

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and test and clean all new pipelines installed under this Contract as specified herein.

1.2 RELATED WORK

A. Buried pipelines are included in Division 2.

B. Above grade and exposed pipelines are included in Division 15.

PART 2 PRODUCTS (NOT USED) PART

3 EXECUTION

3.1 GENERAL

A. Furnish all necessary equipment and labor for cleaning and testing the pipelines. The procedures and methods shall be approved by the Engineer.

B. Make taps and furnish all necessary caps, plugs, etc., as required in conjunction with testing pipelines. Furnish a test pump, gauges and any other equipment required in conjunction with carrying out the hydrostatic tests.

3.2 CLEANING PIPELINES

A. As pipe laying progresses and at the conclusion of the work thoroughly clean all new pipelines by flushing with water or other means to remove all dirt, stones, pieces of wood or other material which may have entered during the construction period. If, after this cleaning, obstructions remain, they shall be removed.

3.3 TESTING GRAVITY PIPELINES

A. All gravity pipelines shall be tested for leakage by an infiltration or exfiltration test. Buried piping shall be tested by an infiltration test if the groundwater is more than 2-ft above the crown of the pipe for the full length of the section to be tested. Air testing may be used in lieu of an exfiltration test subject to approval of the Engineer.

B. Exfiltration Test

1. Leakage tests by exfiltration shall be made by creating a head in the pipeline to be tested by filling the line and either a manhole or temporary riser on one end of the line with water. The length of pipe to be tested shall be such that the head over the

Bid Set April 2017



crown at the upstream end is not less than 2-ft and the head over the downstream crown is not more than 6-ft. The pipe shall be plugged by pneumatic bags or mechanical plugs in such a manner that the air can be released from the pipe while it is being filled with water. Before any measurements are made, the pipe shall be kept full of water long enough to allow absorption and the escape of any trapped air to take place. Following this, a test period of at least one hour shall begin. Provisions shall be made for measuring the amount of water required to maintain the water at a constant level during the test period.

2. If any joint shows an appreciable amount of leakage, the jointing material shall be removed and the joint repaired. If any pipe is defective, it shall be removed and replaced. If the quantity of water required to maintain a constant head in the pipe does not exceed 1.9 gallons per inch of diameter per day per 100-ft of pipe and if all the leakage is not confined to a few joints, workmanship shall be considered satisfactory.

C. Infiltration Test

1. Pipe shall be tested for infiltration after the backfill has been placed and the ground water allowed to return to normal elevation. The length of line to be tested shall be not less than the length between adjacent manholes and not more than the total length of each size of pipe. The allowable infiltration shall be 1.9 gallons per inch of diameter per day per 100-ft of pipe in each section tested. There shall be no gushing or spurting leaks.

2. If an inspection of the completed pipeline or any part thereof shows pipes or joints

which allow noticeable infiltration of water, the defective work or material shall be replaced or repaired as directed.

3. Rates of infiltration shall be determined by means of V-notch weirs, pipe spigots, or by plugs in the end of the pipe installed in an approved manner and at such times and locations as may be directed by the Engineer.

D. When the pipeline to be tested is reinforced concrete pipe, the allowable leakage in the above tests shall be 4.7 gallons per inch of diameter per 100-ft of pipe.

E. Low Pressure Air Test

1. Low-pressure air tests shall be made with equipment specifically designed and manufactured for the purpose of testing pipelines using low-pressure air. The equipment shall be provided with an air regulator valve or air safety valve so set that the internal air pressure in the pipeline cannot exceed 8 psig. Pneumatic plugs shall have a sealing length equal to or greater than the diameter of the pipe to be tested. All air used shall pass through a single control panel.

2. Install plugs at manholes. Brace plugs securely as required for safety and allow no one in the manholes while pressurizing the line or during the test.

3. Low-pressure air shall be introduced into the sealed line until the internal air pressure reaches 4 psig. The internal air pressure in the sealed line shall not be allowed to exceed 8 psig. At least 2 minutes shall be allowed for the air pressure to

Bid Set April 2017



stabilize in the section under test. After the stabilization period, the low-pressure air supply hose shall be quickly disconnected from the control panel. The time required in minutes for the pressure in the section under test to decrease from 3.5 to 2.5 psig shall not be less than that shown in Table 1 of ASTM F1417.

4. If the pipe section does not pass the air test, sectionalize the section tested to

determine the location of the leak. Once the leak has been located, repair and retest.

3.4 TESTING PRESSURE PIPELINES

A. All pressure pipelines shall be pressure and leakage tested. Pipelines shall be subjected to a hydrostatic pressure of 50 percent above the normal operating pressure and this pressure maintained for at least 10 minutes. The leakage test shall be conducted at the maximum operating pressure as determined by the Engineer, and this pressure shall be maintained for at least two hours. The test pump and water supply shall be arranged to allow accurate measurement of the water required to maintain the test pressure. Where applicable, hydrant branch gate valves shall remain open during this test. The amount of leakage which will be permitted shall be in accordance with AWWA C600.

END OF SECTION

Bid Set April 2017




Bid Set April 2017

Tightness Testing of Liquid Retaining Structures 01480-1


SECTION 01480

TIGHTNESS TESTING OF LIQUID RETAINING STRUCTURES

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and perform tightness testing of reinforced concrete liquid retaining structures listed herein and all retesting until the structures meet the requirements specified herein.

1.2 RELATED WORK

A. Concrete joints and joint accessories are included in Section 03250.

B. Cast in place concrete is included in Section 03300.

C. Valves are included in Section 15100.

1.3 SUBMITTALS

A. Submit for each structure, in accordance with Section PR-9, a detailed plan and schedule which shows the method of filling and disposal of water.

B. Submit, in accordance with Section PR-9, a completed Tightness Test Report (Figure A, appended at the end of this Section) of each test for each structure.


A. American Concrete Institute (ACI)

1. ACI 350.1 - Tightness Testing of Environmental Engineering Concrete Structures and Commentary.

B. Where reference is made to the above standard, the revision in effect at the time of bid opening shall apply.

1.5 PROJECT/SITE REQUIREMENTS

A. Coordinate timing and procedures for obtaining water for testing, structure testing, and water disposal with the Owner a minimum of 30 days in advance of the actual testing.

B. Water Source and Disposal

1. Water for testing shall be provided by the Contractor.

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2. Test water shall be disposed of by the Contractor in an approved manner. Water shall not be disposed of by discharging it onto the ground surface of public or private land.


3 EXECUTION

3.1 GENERAL

A. The tightness testing of cast in place reinforced concrete liquid retaining structures shall conform to ACI 350.1 and as specified herein.

B. Whenever practical, perform tightness tests prior to placing backfill around the structure in order to permit observation and detection of leakage points.

3.2 PREPARATION

A. Remove all dirt, mud and debris from the structure prior to initiating tightness tests. The floor and sumps shall be flushed with water to provide a clean surface, ready for testing.

B. Inlet and outlet pipes not required to be operational for the tests shall be temporarily sealed or bulkheaded prior to testing.

C. Confirm that all valves are completely closed. Repair and reset seals if necessary. All valves shall be tested for leakage in accordance with the requirements of the respective Sections as part of the preparation for final tightness testing under this Section. Estimates of valve leakage will not be allowed as adjustments to the measured structure leakage.

3.3 EXAMINATION

A. Inspect the structure to be tested for potential leakage paths including cracks, voids, honeycombs, and unsealed joints and repair such paths as directed by the Engineer, at no additional cost to the Owner.

3.4 TESTING PROCEDURES

A. Conditions of Testing

1. Do not begin filling of reinforced concrete structure until all concrete elements of the structure have attained the specified design strength, but not less than 14 days after all concrete elements have been placed.

2. Filling of reinforced concrete structure shall not exceed a rate of 4-ft in 24 hours.

3. Fill reinforced concrete structure to the maximum operating water surface level and maintain the water at that level for at least 72 hours prior to beginning tightness tests to minimize water absorption by the concrete during testing.

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B. Testing Procedures

1. Duration of the test shall not be less than the time required to produce a drop in the water surface of 1/2-in based on the calculated maximum allowable leakage rate or 3 days, whichever is greater.

2. Measure water surface elevations at 24 hour intervals. Measure water surface elevations at the same four locations 90 degrees apart. Record water temperature 18-in below the water surface when taking the first and last sets of measurements. The methods used to determine the amount of precipitation or evaporation shall be approved by the Engineer.

3. The percentage of water volume loss shall be computed based on the measured change in water surface elevation, the area of the horizontal water surface, the initial water volume and any correction for precipitation or evaporation where applicable.

C. Reports

1. Notify the Engineer and Owner of the scheduling of tests 30 working days prior to the tests. The Engineer may monitor any tightness testing performed on the structures.

2. Submit a completed Tightness Test Report on the form appended to this Section for each structure tested.

3.5 ACCEPTANCE

A. The following conditions shall be considered as NOT meeting the criteria for acceptance regardless of the actual loss of water volume from the structure.

1. Groundwater seeping or flowing into the structure through floors, walls, or wall- floor joints.

2. Structures which exhibit seeping or flowing water from joints, cracks, voids,

honeycombs, or from beneath the foundation.

3. Damp spots on concrete surfaces.

4. Moisture can be deposited on a dry hand held against the exterior surface of the structure.

B. The tightness of concrete tanks and structures shall be considered acceptable when the conditions of Paragraph 3.05 A are not present and when loss of water volume is within the criteria listed below:

1. For unlined (or partially lined) reinforced concrete structures, loss of volume not exceeding 0.10 percent in 24 hours (HST-100).

2. For reinforced concrete structures with fully lined walls, loss of volume not exceeding 0.05 percent in 24 hours (HST-050).

Bid Set April 2017



3.6 REPAIRS AND RETESTING

A. Structures failing the tightness test and not exhibiting visible leakage may be retested after an additional stabilization period of 7 days. Structures failing this second test shall be repaired at no additional cost to the Owner prior to further testing.

B. Repaired structures shall be retested. Repairs and retesting shall be conducted at no additional cost to the Owner and shall be continued and repeated until the structure meets all requirements specified herein.

3.7 SCHEDULE

A. The following structures shall be tested for tightness:

1. Wet Weather Pump Station.

2. Manhole.

Bid Set April 2017



FIGURE A TIGHTNESS TEST REPORT

PROJECT STRUCTURE*

SUBMITTED BY TEST DATES

Allowable loss of water volume percent in 24 hrs. Measured loss of water volume percent in 24 hrs. (From D below)

TEST READINGS Water temperature at start degrees F Water temperature at end degrees F

Water Surface Elevation

Date Time

Location 1

Location 2

Location 3

Location 4

Initials

1. _

_

_

2. _

_

_

3. _

_

_

4. _

_

_

5. _

_

_

Change in level

_

_

A .

Average change in level

B .

Correction for precipitation/evaporation

C .

Corrected change in level = CL =

D .

Measured percent water loss in 24 hrs. = (CL) x (surface area) x (100)

(initial water volume) (number of test days)

Notes and field observations**

* Attach a sketch showing a plan of the structure and measurement locations. ** Place date and initials at the beginning of each entry.

END OF SECTION

Bid Set April 2017




Bid Set

April 2017

Seismic Design Criteria

01612 - 1


SECTION 01612 SEISMIC

DESIGN CRITERIA

PART 1 GENERAL

1.1 SCOPE OF WORK

A. This Section includes seismic design criteria for all nonstructural components and non- building structures, including their supports and anchorage.

B. Design anchorage for components and non-building structures and install them in conformance with the seismic requirements contained in the California Building Code, its referenced standards, and as amended in this Section. Components shall be restrained such that the component forces are transferred to the structure or the component’s foundation.

C. A continuous load path of sufficient strength and stiffness between the component and structure shall be demonstrated through analysis.

D. Components and structures include, but are not limited to:

1. Mechanical equipment.

2. Electrical Equipment.

3. Pipe supports.

4. Pipe support footings.

1.2 SUBMITTALS

A. Complete shop drawings including anchors and base plate settings.

B. Calculations: Submit seismic restraint calculations for all components identified in this Specification. Calculations shall be signed and sealed by a professional civil or structural engineer registered in the State of California. The anchorage selection in the calculations shall reflect what is shown in the appropriate component shop drawing.

C. Seismic Qualification Certification: Submit certification by the supplier that the mechanical or electrical components identified in this Specification will remain operable following the design level earthquake in accordance with ASCE 7 Section 13.2.2. Such certification shall be based on approved shake table testing or experience data. Seismic certification need not be submitted for pre-qualified structurally rugged equipment as listed in Table 01612-1:

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Table 01612-1 Pre-qualified structurally rugged equipment

Valves Engines Motors Generators Turbines Horizontal and vertical pumps Hydraulic and pneumatic operators Motor operators Compressors Small factory-manufactured boilers Transformers with anchored internal coils Air handling equipment and fans (without internal

or external vibration isolators) Low and medium voltage switchgear (<13.8 kV) Instrumentation cabinets Distribution panels Battery chargers Motor control centers Instrument racks Batteries Inverters Chillers

D. In addition to the above requirements, where equipment with complex component structural systems (i.e., systems involving components with multiple degrees of freedom and higher order modes of vibration) contains low weight components (e.g., circuit boards, relays or solenoids), an empirical evaluation for such low weight components shall be certified in writing by a Professional Civil or Structural Engineer registered in the State of California, to satisfy the functionality requirements set forth above. At a minimum, such certification shall be based on an empirical evaluation of direct on-site observation by such equipment to as installed, including physical “hand” shake and pull tests, and general calculations (if required to verify capacity overload) necessary to satisfy such engineer of compliance with the above functionality requirements. Certification shall be in the form of a letter from the registered engineer incorporating the nature of the observations and/or calculations performed including the registered engineer’s seal.


A. 2013 California Building Code (CBC) with 2014 City of Los Angeles Building Code (LABC) amendments.

B. American Society of Civil Engineers (ASCE).

1. ASCE 7-10 – Minimum Design Loads for Buildings and Other Structures.

C. American Concrete Institute (ACI).

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1. ACI 318 – Building Code Requirements for Structural Concrete.


A. Design Requirements: Design in accordance with the CBC, LABC and the criteria herein. Components shall be restrained or anchored such that the component forces are transferred to the structure.

1. Supports for equipment and components shall be designed to conform to the requirements set forth in CBC, LABC and ASCE 7 using the following modifications and parameters:

a. Soil Site Class: D.

b. Mapped Spectral Response Accelerations: SS

= 1.655 g. S1 = 0.616 g.

c. Spectral Response Accelerations: SDS = 1.103 g. SD1 = 0.616 g.

d. Risk Category: II Ie = 1.0, Ip = 1.0

e. Response modification factor (Rp): ASCE 7 Tables.

2. Support for equipment and components shall be designed to maintain integrity and functionality after being subjected to a seismic load.

a. The minimum horizontal seismic force applied to equipment, tank, or component in any direction.

b. In addition to the horizontal seismic forces, a concurrent vertical seismic force of 0.2SDS times the component weight shall be applied to the equipment, tank or component.

c. Neglect vertical effects where inclusion of vertical loads results in a less conservative design.

3. Use cast-in anchors or post-installed anchors for resisting seismic forces.

a. Anchors shall be designed in accordance with Appendix D of ACI 318 and/or the relevant ICC or IAPMO evaluation reports and LADBS research report assuming cracked concrete. Post-installed anchors shall have current ICC or IAPMO evaluation reports and LADBS research report indicating the anchors are suitable to resist seismic loads in cracked concrete.

b. Cast-in anchors or headed studs shall be used whenever possible. Expansion anchors shall not be used for critical fastening such as extreme vibrating conditions and impact loads.

c. Adhesive anchors shall not be used in areas that could experience high temperatures to support emergency egress elements of the structures, or in overhead applications. Cast-in anchors shall not be wet set into concrete or grout.

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d. Seismic forces shall be resisted by direct bearing on the fasteners used to resist seismic forces. Do not use connections which rely on friction from gravity to resist seismic forces.

e. See Section 05500 for additional requirements.


A. Testing and special inspection of anchorage shall be performed in accordance with Chapter 17 of the CBC.

B. Testing and special inspection will be paid for by the OWNER.

C. The Special Inspector shall keep a record of inspections and furnish inspection reports to the OWNER and ENGINEER. The reports shall indicate that work inspected was performed in conformance with the Contract Documents. Discrepancies shall be brought to the immediate attention of the OWNER. A final report of inspections documenting required special inspections and correction of any discrepancies noted in the inspections shall be submitted periodically at a frequency agreed upon at the start of work.

D. Testing shall be required as outlined below in addition to that specified in Chapter 17 of the CBC, unless specific testing requirements are provided in other Sections.

1. Anchors for Piping. A minimum of 10 percent of the anchors installed in concrete shall be tested for tension for 160 percent of the allowable tension. Anchors that fail the test shall be removed and replaced. In addition, the testing shall be expanded to all anchors installed on the same day as the failed anchor by the same crew.

2. Anchors for other components, non-structural items, and non-building structures. A minimum of 20 percent of anchors installed in concrete shall be tested in tension for 160 percent of the allowable tension. Anchors that fail the test shall be removed and replaced. In addition, the testing shall be expanded to all anchors installed on the same day as the failed anchor by the same crew. Major pieces of equipment shall have a minimum of two anchor bolt tension tests.

PART 2 PRODUCTS

2.1 ANCHORS - GENERAL

A. For components weighing 400 pounds or more using cast-in-place anchors, the minimum anchors size shall be 5/8-inch with minimum 5-inch embedment and as required by submitted seismic calculations.

B. For components weighing 400 pounds or more using post-installed anchors, the minimum anchor size shall be as required by submitted seismic anchorage calculations.

C. For all components weighing less than 400 pounds, the minimum anchor size shall be

3/8-inch diameter with minimum 3-inch embedment.

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D. All anchors securing components to be grouted shall be furnished with leveling nuts, the faces of which shall be tightened against flat surfaces to not less than 10 percent of the bolt’s safe tensile stress.

E. See Specification 05500 for post-installed anchors.

PART 3 EXECUTION

3.1 GENERAL

A. All components designed to be fixed in position shall be securely fastened in place in conformance with the CBC, ASCE 7, and as specified herein. For other components the component manufacturer shall provide recommended anchorage information to the CONTRACTOR for use in component installation.

3.2 STRUCTURAL INTEGRITY AND ANCHORAGE

A. It shall be the responsibility of the component manufacturer/supplier to provide the engineering anchorage calculations and figures to the Contractor for submission to the Engineer. As a minimum, the component manufacturer/supplier shall determine the supplier, type, number, dimensions, material, location, embedment, and installation conditions of all anchors to be installed in accordance with these Specifications and Drawings.

B. Engineering anchorage calculations and figures shall be prepared and sealed by a Professional Civil or Structural Engineer registered in the State of California. Calculations shall include the following steps as a minimum:

1. Indicate parameters used to determine demand lateral loads including ap, Rp, z, hr, SDS, importance factor, operating weight and component center-of-mass.

2. Determine the component shear and moment due to application of the seismic force at the component's centroid.

3. Determine the shear and tension forces at each anchor due to application of the seismic force at the component’s centroid.

4. Determine anchor capacities in accordance with ACI 318 Appendix D, any applicable ICC, IAPMO, or LADBS Evaluation Service Reports, while accounting for concrete compressive strength and thickness of slab or topping slab.

5. Selection of anchors based upon the maximum shear and tension forces calculated above.

6. Include details indicating number of bolts, materials, diameter, total length, embedded length, required edge distance, and bolt dimensions. The embedded length of bolts shall be suitable to develop the ultimate tensile capacity of the anchorage for ductile failure.

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7. Where vibration isolation devices are used, include manufacturer’s product information indicating class and type. Indicate load ratings as published in manufacturer’s data or shop drawings. Indicate proper orientation of devices in plan.

8. Anchors shall be designed to resist the lateral seismic force in at least two orthogonal

directions in combination with component service loads, as appropriate.

9. Include vertical seismic effects in accordance with ASCE 7 in the anchor design. However, neglect vertical seismic effects where inclusion of vertical loads results in a less conservative design.

END OF SECTION

Bid Set

April 2017

Wind Design Criteria

01614 - 1


SECTION 01614 WIND

DESIGN CRITERIA

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Provide structural design due to the action of wind for project components and systems to be designed by performance specification. Design of all components and systems shall be done by a Professional Engineer engaged by and at the expense of the Contractor.

B. This Section contains requirements regarding applicable codes, basis of design, and load criteria to be used in the detailed design of project components and systems to be designed under other Sections.

C. Furnish calculations for all loads and load combinations as specified herein.

D. The wind design criteria specified herein apply to the design of the following components and systems, and other components and systems specified under other Sections:

1. Pre-engineered Metal Canopies

2. Pipes and Pipe Supports 1.2 RELATED WORK

A. Seismic Design Requirements are included in Section 01612.

B. Cast-in-place concrete is included in Section 03300.

C. Grout is included in Section 03600.

D. Miscellaneous metals are included in Section 05500.

E. Pre-engineered canopy is included in Section 13120.

1.3 SUBMITTALS

A. Submit, in accordance with Section PR-9, design calculations and Shop Drawings, including the following:

1. Calculations signed and sealed by a professional civil or structural engineer registered in the State of California for project records.

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2. Detailed Shop Drawings showing complete plans, elevations, sections, details and connection details or anchor bolt details as applicable. Submittals shall be clear and legible and of sufficient size for presentation of data.


A. International Code Council (ICC)

1. International Building Code (IBC) 2012

2. ICC Evaluation Service Reports

B. International Association of Plumbing and Mechanical Officials (IAPMO)

1. IAPMO Evaluation Service Reports

C. City of Los Angeles Department of Building and Safety (LABDS)

1. LABDS Research Reports

D. California Building Commission

1. California Building Code (CBC) 2013 with 2014 Los Angeles Building Code (LABC) Amendments.

E. ASCE 7 –10 Minimum Design Loads for Buildings and Other Structures

1.05

SYSTEM DESCRIPTION

A. The following basic wind design criteria shall be used in all calculations. All other

factors shall be determined in accordance with ASCE 7.

1. Basic Wind Speed: V= 110 miles per hour.

2. Wind Exposure Category: C.

B. Use Envelope Procedure in accordance with Chapters 28 and 30 of ASCE 7 for the

following structures:

1. Pre-engineered Metal Canopies

C. Use Directional Procedure in accordance with Chapters 27, 29, and 30 of ASCE 7 for

the following structures:

1. Pipes and Pipe Supports

2. Equipment and Equipment enclosures

3. All other structures not specifically listed

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1.6 COMBINATION OF LOADS

A. Wind loads shall be used in combination with all other applicable design loads including but not limited to: dead loads, live loads, rain loads, snow loads, ice loads, seismic loads, flood loads, earth and ground water pressures, and self-straining in accordance with the load combinations of ASCE 7 and the project building code.

B. The most severe distribution, concentration and combination of design loads and forces shall be determined and then used in the design in accordance with the project building code. Some combinations of design loadings can be eliminated based on practical considerations. The referenced codes permit stress increases for some combinations but not for others. Design to meet code requirements and to satisfy all combinations of loads.

PART 2 PRODUCTS

2.1 GENERAL

A. All products shall meet the requirements of the project building code.

B. All anchors shall be used in accordance with current ICC or IAPMO Evaluation Service Evaluation Reports and LADBS Research Reports.

PART 3 EXECUTION

3.1 GENERAL

A. Wind design criteria shall be used in conjunction with the appropriate load factors and load combinations in accordance with ASCE 7 and the project building code.

END OF SECTION

Bid Set

April 2017


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Bid Set April 2017

Demolition 02050-1


SECTION 02050

DEMOLITION

PART 1 GENERAL 1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and demolish, modify,

remove and dispose of work shown on the Drawings and as specified herein.

B. Included, but not limited to, are demolition, modifications and removal of existing materials, equipment or work necessary to install the new work as shown on the Drawings and as specified herein and to connect with existing work in approved manner.

C. Demolition, modifications and removals which may be specified under other Sections

shall conform to requirements of this Section.

D. Demolition includes but is not limited to:

1. Curb and gutter

2. Existing fence

3. Site pavement

4. Site fencing

E. Blasting and the use of explosives will not be permitted for any demolition work.

F. Results of a recent investigative survey indicate the presence of lead-based paint (LBP) on

various surfaces located throughout the existing building. Prior to the start of any demolition or new construction work, the Contractor shall comply with all applicable local, county, state and federal regulations which govern lead-based paint work, removal, handling, hauling and disposal of lead-based paint waste materials. These regulations include but are not limited to the following:

1. U.S. Department of Labor, Occupational Safety and Health Administration, 29 CFR 1926.59, Hazard Communication.

2. U.S. Department of Labor, Occupational Safety and Health Administration, 29 CFR 1926.62, Lead in Construction.

3. U.S. Department of Labor, Occupational Safety and Health Administration, 29 CFR 1926.354, Welding, cutting and heating in way of preservative coatings.

4. U.S. Environmental Protection Agency, 40 CFR 261, Identification and Listing of Hazardous Waste.

5. U.S. Department of Labor, Occupational Safety and Health Administration, NESHAP, 40 CFR 50.12, Emissions Standards.

6. Lead-Based Paint Poisoning Prevention Act (LBPPPA), 1970.

7. Title 10 – LBP Hazard Reduction Act, 1992, (amendment for LBPPPA, 1970).

8. Resource Conservation Recovery Act (RCRA).

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Demolition 02050-2


9. California Department of Health Services, Title 17, California Code of Regulations, Division 1, Chapter 8 Accreditation, Certification and work practices for lead-based paint and lead hazards.

10. California Occupational Safety and Health Administration (CAL-OSHA), Title8, CCR 1532.1, Lead in Construction.

G. Results of a recent investigative survey indicate the presence of Asbestos within various

materials located throughout the existing building. Prior to the start of any demolition or new construction work, the Contractor shall comply with all applicable local, county, state and federal regulations which govern abatement work, removal, handling, hauling and disposal of asbestos waste materials. These regulations include but are not limited to the following:

1. U.S. Department of Labor, Occupational Safety and Health Administration (OSHA), Title 29, Parts 1910 and 1926, Asbestos Regulations as required.

2. Environmental Protection Agency (EPA), 40 CFR Part 763, Subpart G, CPTS 62044, FLR 2843-9, Federal Register, Vol. 50, No. 134, 1985, Worker Protection Rule.

3. Environmental Protection Agency (EPA), Title 40, Part 61, Subpart A of the Code of Federal Regulations, Regulation for Asbestos.

4. Environmental Protection Agency (EPA), 40 CFR Part 61, Subpart M of the Code of Federal Regulations, NESHAP Revision; Final Rule, Federal Register, 1990,

5. Environmental Protection Agency (EPA), Regulations 40 CFR, Part 763, Subpart E, Asbestos Hazard, Emergency Response Act (AHERA).

6. U.S. Department of Transportation (DOT), Regulation 49 CFR, Parts 171, 172 and 173, Hazardous Substances, Final Rule.

7. Uniform Fire Code (UFC), Section 87.106, 87.102, Asbestos Removal.

8. American National Standards Institute (ANSI), Publication Z9.2-1979, Fundamentals Governing the Design and Operation of Local Exhaust Systems.

9. American National Standards Institute (ANSI), Publication Z88.2-1980, Practices for Respiratory Protection.

10. American Society for Testing and Materials, ASTM E1368, Standard Practice for Visual Inspection of Asbestos Abatement Projects.

11. National Institute for Occupational Safety and Health (NIOSH).

H. Prior to any demolition, the Contractor shall perform the following removal and abatement activities:

1. Health and safety plan development and implementation.

2. Asbestos abatement as specified herein.

3. Lead-based paint abatement as specified herein.

1.2 RELATED WORK

A. Submittals are included in Section 01300.

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1.3 SUBMITTALS

A. Submit, in accordance with Section 01300, six copies of proposed methods and operations of demolition of the structures and modifications prior to the start of work. Include in the schedule the coordination of shutoff, capping and continuation of utility service as required.

B. Furnish a detailed sequence of demolition and removal work to ensure the uninterrupted

progress of the Owner's operations. Sequence shall be compatible with sequence of construction.

C. Before commencing demolition work, all modifications necessary to bypass the affected

structure shall be completed. Actual work shall not begin until the Engineer has inspected and approved the modifications and authorized commencement of the demolition work in writing.

1.4 JOB CONDITIONS

A. Protection

1. Execute the demolition and removal work to prevent damage or injury to structures, occupants thereof and adjacent features which might result from falling debris or other causes, and so as not to interfere with the use, and free and safe passage to and from adjacent structures.

2. Closing or obstructing of roadways, sidewalks and passageways adjacent to the work by the placement or storage of materials will not be permitted and all operations shall be conducted with a minimum interference to traffic on these ways.

3. Erect and maintain barriers, lights, sidewalk sheds and other required protective devices.

B. Scheduling

1. Carry out operations so as to avoid interference with operations and work in the existing facilities.

C. Notification

1. At least 48 hours prior to commencement of a demolition or removal, notify the Engineer in writing of proposed schedule therefor. Owner shall inspect the existing equipment and to identify and mark those items which are to remain the property of the Owner. No removals shall be started without the permission of the Engineer.

D. Conditions of Structures

1. The Owner and the Engineer assume no responsibility for the actual condition of the structures to be demolished or modified.

2. Conditions existing at the time of inspection for bidding purposes will be maintained by the Owner insofar as practicable. However, variations within a structure may occur prior to the start of demolition work.

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E. Repairs to Damage

1. Promptly repair damage caused to adjacent facilities by demolition operation when directed by Engineer and at no additional cost to the Owner. Repairs shall be made to a condition at least equal to that which existed prior to construction.

F. Traffic Access

1. Conduct demolition and modification operations and the removal of equipment and debris to ensure minimum interference with roads, streets, walks both onsite and offsite and to ensure minimum interference with occupied or used facilities.

2. Special attention is directed towards maintaining safe and convenient access to the existing facilities by plant personnel and plant associated vehicles.

3. Do not close or obstruct streets, walks or other occupied or used facilities without permission from the Engineer. Furnish alternate routes around closed or obstructed traffic in access ways.

1.5 RULES AND REGULATIONS

A. The California Building Code, 2001 Edition, shall control the demolition, modification or

alteration of the existing buildings or structures.

B. No building or structure, or any part thereof, shall be demolished until an application has been filed with the Building Inspector and a permit issued. The fee for this permit shall be the Contractor's responsibility.

1.6 DISPOSAL OF MATERIAL

A. Salvageable material and equipment shall become the property of the Owner.

Dismantle all such items to a size that can be readily handled and deliver them to a designated storage area.

B. All other material and items of equipment shall become the Contractor's property and

must be removed from the site.

C. The storage or sale of removed items on the site will not be allowed. PART 2 PRODUCTS (NOT USED)

PART 3 EXECUTION

3.1 GENERAL

A. All materials and equipment removed from existing work shall become the property of the Contractor, except for those that the Owner has identified and marked for his/her use. All materials and equipment marked by the Owner to remain shall be carefully removed, so as not to be damaged, cleaned and stored on or adjacent to the site in a protected place specified by the Engineer or loaded onto trucks provided by the Owner.

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B. Dispose of all demolition materials, equipment, debris and all other items not marked by the Owner to remain, off the site and in conformance with all existing applicable laws and regulations.

C. Pollution Controls

1. Use water sprinkling, temporary enclosures and other suitable methods to limit the amount of dust and dirt rising and scattering in the air to the lowest practical level. Comply with governing regulations pertaining to environmental protection.

a. Do not use water when it may create hazardous or objectionable conditions

such as ice, flooding and pollution.

b. Clean adjacent structures, facilities, and improvements of dust, dirt and debris caused by demolition operations. Return adjacent areas to conditions existing prior to the start of the work.

D. Building Demolition

1. Unless otherwise approved by Engineer, proceed with demolition from the top of the structure to the ground. Complete demolition work above each floor or tier before disturbing supporting members of lower levels.

2. Demolish concrete and masonry in small sections.

3. Remove structural framing members and lower to ground by means of hoists, derricks, or other suitable methods.

4. Break up and remove foundations and slabs-on-grade, unless otherwise shown to remain.

5. Locate demolition equipment throughout the structure and remove material so as to not impose excessive loads to supporting walls, floors or framing.

3.2 STRUCTURAL REMOVALS

A. Remove structures to the lines and grades shown unless otherwise directed by the

Engineer. Where no limits are shown, the limits shall be 4-in outside the item to be installed. The removal of masonry beyond these limits shall be at the Contractor's expense and these excess removals shall be reconstructed to the satisfaction of the Engineer with no additional compensation to the Contractor.

B. All concrete, brick, tile, concrete block, roofing materials, reinforcement, structural or

miscellaneous metals, plaster, wire mesh and other items contained in or upon the structure shall be removed and taken from the site, unless otherwise approved by the Engineer. Demolished items shall not be used in backfill adjacent to structures or in pipeline trenches.

C. After removal of parts or all of masonry walls, slabs and like work which tie into new

work or existing work, the point of junction shall be neatly repaired so as to leave only finished edges and surface exposed.

3.3

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MECHANICAL REMOVALS

A. Mechanical removals shall consist of dismantling and removing of existing septic systems, piping, pumps, motors, equipment and other appurtenances as specified, shown, or required for the completion of the work. It shall include cutting, capping, and plugging as required, except that the cutting of existing piping for the purpose of making connections thereto will be included under Division 15.

B. Existing process, water, chemical, gas, fuel oil and other piping not required for the new

work shall be removed where shown or where it will interfere with new work. Piping not indicated to be removed or which does not interfere with new work shall be removed to the nearest solid support, capped and left in place. Chemical and fuel lines and tanks shall be purged and made safe prior to removal or capping. Where piping that is to be removed passes through existing walls, it shall be cut off and properly capped on each side of the wall.

C. When underground piping is to be altered, or removed, the remaining piping shall be

properly capped. Abandoned underground piping may be left in place unless it interferes with new work or is shown or specified to be removed.

D. Waste and vent piping shall be removed to points shown. Pipe shall be plugged with

cleanouts and plugs. Where vent stacks pass through an existing roof that is to remain, they shall be removed and the hole in the roof properly patched and made watertight.

E. Any changes to potable water piping and other plumbing and heating system work shall be

made in conformance with all applicable codes and under the same requirements as other underground piping. All portions of the potable water system that have been altered or opened shall be pressure tested and disinfected in accordance with AWWA Standards and local codes. Other plumbing piping and heating piping shall be pressure tested only.

3.4 ELECTRICAL REMOVALS

A. Electrical removals shall consist of the removal of existing transformers, distribution

switchboards, control panels, motors, conduits and wires, poles and overhead wiring, panelboards, lighting fixtures and miscellaneous electrical equipment all as shown on the Drawings, specified herein, or required to perform the work.

B. All existing electrical equipment and fixtures to be removed shall be removed with such

care as may be required to prevent unnecessary damage, to keep existing systems in operation and to maintain the integrity of the grounding systems.

C. Conduits and wires shall be abandoned or removed where shown. All wires in abandoned

conduits shall be removed, salvaged and stored. Abandoned conduits concealed in floor or ceiling slabs or in walls, shall be cut flush with the slab or wall at the point of entrance. The conduits shall be suitable plugged and the area repaired in a flush, smooth and approved manner. Exposed conduits and their supports shall be disassembled and removed from the site. Repair all areas of work to prevent rust spots on exposed surfaces.

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D. Where shown or otherwise required, wiring in the underground duct system shall be removed. All such wiring shall be salvaged and stored as specified. Verify the function of all wiring before disconnection and removing it. Ducts which are not to be reused shall be plugged where they enter buildings and made watertight.

E. Where shown, direct-burial cable shall be abandoned. Such cable shall be disconnected

at both ends of the run. Where it enters a building, or structure, the cable shall be cut back to the point of entrance. All opening in buildings for entrance of abandoned direct-burial cable shall be patched and made watertight.

F. Poles and overhead wiring shall be abandoned as shown and specified. Existing

substation and poles owned by the power company will be removed by the power company. Poles not owned by the power company shall be completely removed from the site. The overhead wires shall be salvaged and stored. Perform this work after the proposed service has been completed and energized, and in accordance with the approved schedule.

G. Lighting fixtures shall be removed or relocated as shown. Fixtures not relocated shall be

removed from the site. Relocated fixtures shall be carefully removed from their present location and rehung where shown.

H. Wall switches, receptacles, starters and other miscellaneous electrical equipment, shall be

removed and disposed of off the site as required. Care shall be taken in removing all equipment to minimize damage to architectural and structural members. Any damage incurred shall be repaired.

3.5 LEAD-BASED PAINT HANDLING AND DISPOSAL REQUIREMENTS

A. The Contractor shall refer to the Contractor licensed by the State of California for

performing the lead-based paint removal work of this Section.

B. Prior to commencing demolition activities, the Contractor shall complete and sign certification of compliance with OSHA 29 CFR 1926.62. This certification attests that the Contractor has prepared and implemented a written Lead Compliance Plan.

C. The Contractor shall properly remove all LBP coatings for a distance of at least 4 inches

from areas of heat application prior to any welding, cutting or torching. Containerize lead-based paint coatings in 55-gallon drums for disposal as a D008 hazardous waste and dispose of all lead-based paint coatings in accordance with all applicable local, state and federal regulations.

D. The Contractor shall notify recycling facilities in writing of the presence of LBP. The

Contractor shall obtain a letter from each recycling facility, acknowledging that there is LBP in the wastestream(s) being accepted for recycling and that the presence of LBP does not preclude acceptance of the material at the facility.

E. For waste streams that will be disposed of off-site at Construction and Demolition (C&D)

landfills, the Contractor shall perform sufficient testing to document that the waste streams are not a RCRA characteristic hazardous waste. TCLP-lead testing is not required for wastestreams that are recycled.

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F. For wastestreams that will be disposed of at C&D landfills, collect and analyze a sufficient number of representative material samples to obtain a statistically valid data base as defined in EPA testing Method SW-846. At a minimum, one sample shall be collected and analyzed per waste stream. The Contractor shall analyze representative material samples for TCLP lead in accordance with EPA Method 1311/6010 with a 2-day turnaround time using a laboratory certified by the State of California. The following information will be submitted to the Engineer for review within one week of receipt of laboratory test results:

1. A description of the waste stream materials tested

2. Sample locations

3. Laboratory test results

G. Disposal of LBP coated waste streams cannot occur until after the Engineer has reviewed the laboratory test results.

3.6 ASBESTOS HANDLING AND DISPOSAL REQUIREMENTS

A. The Contractor shall refer to the Asbestos Abatement Contractor licensed by the State of

California for performing the abatement work of this Section.

B. The Contractor shall provide and pay for all necessary notifications, permits and licenses related to the Work required by this Section.

1. Assure that written notification as required by USEPA National Emission Standards for Hazardous Air Pollutants (NESHAPS) Asbestos Regulations (40 CFR 61, Subpart M) has been sent to and received by the regional Asbestos NESHAPS Contact at least 10 days prior to beginning any work on asbestos-containing materials.

2. State and Local Agencies: Send written notification as required by the regulations of the State of California, County of San Bernardino and City of Fontana prior to beginning any work on asbestos-containing materials.

3. Licenses: Maintain current licenses as required by applicable state or local jurisdictions for the removal, transporting, disposal or other regulated activity relative to the work of this Contract.

4. Posting and Filing of Regulations: Maintain two copies of the applicable Federal, State and local regulations above. Post one copy of each at the job site and keep one copy of each regulation file in the Contractor's office.

C. The Contractor shall provide all workers, foremen, superintendents, authorized visitors,

and inspectors personally-issued and marked respiratory protective equipment approved by NIOSH and OSHA. When respirators with disposable filters are employed, the Contractor shall provide sufficient filters for replacement as necessary by the worker or authorized visitor. Filters shall be disposed of as contaminated waste.

D. The Contractor shall package, label and remove all asbestos waste from the work area in

a manner that meets or exceeds all required regulations. Packaging shall be accomplished in a manner that minimizes waste volume, but insures waste containers shall not tear or break. Transportation and disposal of the containerized waste at an acceptable location shall be the responsibility of the Contractor.

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Demolition 02050-9


3.7 CLEAN-UP

A. Remove from the site all debris resulting from the demolition operations as it accumulates. Upon completion of the work, all materials, equipment, waste and debris of every sort shall be removed and premises shall be left, clean, neat and orderly.

END OF SECTION

Bid Set April 2017

Demolition 02050-10



Bid Set April 2017

Earthwork 02200-1


SECTION 02200

EARTHWORK

PART 1 GENERAL 1.1 STATUTORY REQUIREMENTS

A. All excavation, trenching, sheeting, bracing, etc., shall comply with the requirements of

OSHA excavation safety standards (29 CFR Part 1926.650 Subpart P), and all applicable state and local requirements. Where conflict between OSHA, state and local regulations exists, the most stringent requirements shall apply.

1.2 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals necessary to perform all

excavation work and grading; place and compact backfill and fill; and dispose of unsuitable, waste and surplus materials as shown on the Drawings and as specified herein.

B. Provide the services of a licensed professional civil engineer, registered in the state in

which the Work is located, to prepare temporary excavation support system designs and submittals.

C. Furnish and install temporary excavation support systems, including sheeting, H-piling,

lagging, shoring and bracing, to insure the safety of personnel and protect adjacent structures, piping, etc, in accordance with federal, state and local laws, regulations and requirements.

1.3 RELATED WORK

A. Trenching, Backfilling and Compaction is included in Section 02221.

B. Granular Fill Materials are included in Section 02230.

D Demolition and Modifications is included in Section 02050.

1.4 SUBMITTALS

A. Excavation support system designs shall be prepared by a licensed professional civil

engineer, registered in the state in which the Work is located, having a minimum of five years of professional experience in the design and construction of excavation support systems. Submit an original and three copies of the licensed professional engineer's certification, on the PE form specified in Section 01300, stating that the excavation support systems designs have been prepared by the professional engineer and that the professional engineer will be responsible for their execution. Do not submit excavation support system designs unless requested in writing.


A. American Society for Testing and Materials (ASTM)

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1. ASTM D698 - Standard Test Methods for Moisture-Density Relations of Soils and Soil-Aggregates Mixtures Using 5.5 lbs (2.49 kg) Rammer and 12-in (305-mm) Drop. (Also known as Standard Proctor Analysis)

2. ASTM D1557 - Standard Test Methods for Moisture-Density Relations of Soils and

Soil-Aggregate Mixtures, using 10-lb (4.54 kg) Rammer and 18-in (457 mm) Drop. (Also known as Modified Proctor Analysis)

3. ASTM D1682 - Standard Test Method for Breaking Load and Elongation of Textile

Fabrics.

B. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.


A. At all structures, prior to the placement of bedding material, concrete work mats,

structural fill or structural concrete, coordinate with the soils testing laboratory to verify the suitability of the existing subgrade soil and perform in-place soil density tests as required to verify that the bearing capacity of the subgrade is sufficient.

B. Prior to and during the placement of backfill and fill, coordinate with the soils testing

laboratory to perform in-place soil density tests to verify that the backfill/fill material has been compacted in accordance with the compaction requirements specified elsewhere. The Engineer may designate areas to be tested.

1.7 DEFINITIONS

A. Where the phrase "in-the-dry" is used in these Specifications, it shall be defined to mean a

soil condition such that the in-place moisture content of the soil at that time is no more than ten percentage points above the optimum moisture content of that soil as determined by the laboratory test of the moisture-density relation appropriate to the specified level of compaction.

B. Where used in this Specification "structures" refers to all buildings, wet wells, sumps,

manholes, slabs on grade and below grade vaults. Stormwater structures and duct banks are not considered structures in this context.

1.8 SOIL COMPACTION TESTING

A. Prior to general placement of fill and during such placement, the Engineer may select

areas within the limits of fill for testing the degree of compaction obtained. The Contractor shall cooperate fully in obtaining the information desired.

B. Payment for compaction testing will be made by the Owner. If test results are

unsatisfactory, all costs involved in correcting deficiencies in compacted materials to the satisfaction of the Engineer, will be borne by the Contractor. Costs to retest will also be borne by the Contractor. It is understood and agreed that the making of tests shall not constitute an acceptance of any portion of the work or relieve the contractor from compliance with the terms of the contract documents.

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Earthwork 02200-3


PART 2 PRODUCTS 2.1 GENERAL

A. Materials designated for use in this Section are specified in Section 02230.

B. Timber used for excavation support systems shall be pressure treated with wood

preservative for ground contact. PART 3 EXECUTION

3.1 PREPARATION

A Test Pits (Potholes)

1. Perform exploratory excavation work (test pits) for the purpose of verifying the

location of underground utilities and structures and to check for unknown utilities and structures, prior to commencing excavation work.

2. Test pits shall be backfilled as soon as the desired information has been obtained.

Backfilled surfaces shall be stabilized in accordance with approved erosion and sedimentation control plans.

B Dewatering and Drainage Systems

1. If needed, temporary dewatering and drainage systems shall be in place and

operational prior to beginning excavation work, as required herein and in Sections 02140 and 02270.

2. Water entering the excavation from surface runoff shall be collected in shallow ditches

around the perimeter of the excavation, drained to sumps and pumped from the excavation to maintain a bottom free from standing water.

3. Take all additional precautions to prevent uplift of any structure during construction.

4. Drainage shall be disposed of in an approved area only so that flow or seepage

back into the excavated area will be prevented.

5. Take all necessary precautions to preclude the accidental discharge of fuel, oil, etc., in order to prevent adverse effects on groundwater quality.

3.2 EXCAVATION SUPPORT

A. Furnish, install, monitor and maintain excavation support (e.g., shoring, sheeting,

H-piling, lagging, bracing, trench boxes, etc) as required by Federal, State or local laws, ordinances, regulations and safety requirements. Support the sides of excavation, to prevent any movement which could in any way reduce the width of the excavation below that necessary for proper construction and protect adjacent structures from undermining, settlement or other damage. If the Engineer, at any point, is of the opinion that sufficient or proper supports have not been provided, he may order additional supports be put in,

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Earthwork 02200-4


and compliance with such order shall not relieve or release the Contractor from his responsibility for the sufficiency of such supports. Take care to prevent the formation of voids outside of support system. If voids occur behind the support system, immediately backfill and compact the voids with common fill material. Voids in locations that cannot be properly compacted upon backfilling shall be filled with lean concrete.

B. Install excavation supports outside the neat lines of foundations. Supports shall be plumb

and securely braced and tied in position. Excavation support shall be adequate to withstand all pressures to which the supports will be subjected. Any movement or bulging of supports shall be corrected to provide the necessary clearances, dimensions and structural integrity.

C. Where a support system is required to support the sides of excavations, the Contractor

shall engage a Professional Civil Engineer, registered in the state in which the work is located, to design the support system. The support system installed shall be in conformity with the design. Certification of this shall be provided by the Professional Engineer. Prior to the start of excavation, Contractor shall submit P.E. Certification Form contained in Section 01300 to show compliance with this requirement. The Contractor shall be solely responsible for any and all liabilities which may arise from his failure to provide adequate support system or sloping back the excavation as necessary to support the excavation under all conditions of loading which may exist or which may arise during the construction of the project.

D. Excavation Supports Left in Place

1. Excavation supports that are required to remain in place, if applicable, are indicated on

the Drawings.

2. The Owner or Engineer may direct that certain excavation supports remain in place, or be cut off at any specific elevation. Supports directed by the Owner or Engineer to be left in place and not so designated on the Drawings or otherwise specified herein to remain in place, will be paid for in accordance with Article 11 of the General Conditions. If the Contractor believes that such a directive increases Contractor's cost and would thereby entitle Contractor to a change in contract cost, Contractor shall notify the Engineer in accordance with the applicable article(s) in the General Conditions pertaining to changes in the work.

3. The right of the Owner or Engineer to direct that certain excavation supports remain in

place shall not be construed as creating any obligation on the Owner or Engineer to give such direction, nor shall failure to give such direction relieve the Contractor from liability for damages to persons or property occurring from or upon the work occasioned by negligence or otherwise, growing out of a failure on the part of the Contractor to leave in place sufficient excavation supports to prevent any movement of the ground or damage to adjacent structures.

E. Excavation supports shall be carefully removed in such manner so as not to endanger the

Work or other adjacent structures, utilities, or property. All voids left or caused by withdrawal of supports shall be immediately filled with sand and compacted by ramming with tools especially adapted to that purpose, or as otherwise may be acceptable to the Engineer.

Bid Set April 2017

Earthwork 02200-5


3.3 STRUCTURAL EXCAVATION PROCEDURES

A. Excavations for structures shall be suitably wide for construction of the structures, including excavation supports, dewatering and drainage systems and working clearances.

B. Excavation shall be performed in-the-dry and shall be accomplished by methods which

preserve the undisturbed state of subgrade soils. Drainage and dewatering systems shall be in place and operational prior to beginning excavation work. In no case shall the earth be plowed, scraped or excavated by any means so near to the finished subgrade that would disturb the finished subgrade. Hand excavation of the final 3 to 6- in may be required to obtain a satisfactory, undisturbed subgrade. Subgrade soils which become soft, loose, "quick", or otherwise unsatisfactory for support of structures as a result of inadequate excavation, dewatering, or other construction methods shall be removed and replaced with lean concrete, compacted structural fill or suitable crushed rock, subject to prior approval by the Engineer, at no additional cost to the Owner.

C. Subgrade Preparation

1. All structures unless otherwise shown on the Drawings or otherwise specified

herein:

a. Compact the top 24 inches of subgrade to a minimum of 95 percent modified proctor (ASTM D1557).

b. Where structures are supported by piles, compact the top 12 inches of

subgrade to a minimum of 95 percent standard proctor (ASTM D698).

2. In accordance with recommendations made by the geotechnical engineer, all fill within 5 feet of the existing grade shall be entirely removed and re-compacted for support of shallow footings and slab-on-grade. Removal and re-compaction should extend 5 feet beyond the structure limits.

D. When excavations have reached the required subgrade, including any allowances for

working mats or base materials, prior to the placement of working mats or base materials, notify the soils testing laboratory to verify the suitability of the existing subgrade soils for the anticipated foundation and structural loadings. If the existing subgrade soils are determined to be unsuitable, direction will be provided by the Engineer regarding removal and replacement with suitable materials. If Contractor believes that such direction would increase Contractor's cost and would thereby entitle Contractor to a change in Contract cost, Contractor shall notify the Engineer in accordance with the applicable article(s) in the General Conditions pertaining to changes in the work.

3.4 GENERAL FILLING AND BACKFILLING PROCEDURES

A. Fill and backfill materials shall be placed in lifts to suit (not to exceed 8 inches when

loose) the specified compaction requirements to the lines and grades required, making

Bid Set April 2017

Earthwork 02200-6


allowances for settlement and placement of cover materials (i.e. topsoil, sod, etc). Soft spots or uncompacted areas shall be corrected.

B. Compaction in open areas may be accomplished by any of the following methods:

compaction equipment, fully loaded ten-wheel trucks, tractor dozers weighing at least 30,000 lbs and operated at full speed, or heavy vibratory rollers. Compaction in confined areas (including areas within a 45-degree angle extending upward and outward from the base of a wall) and in areas where the use of large equipment is impractical, shall be accomplished by hand operated vibratory equipment or mechanical tampers. Lift thickness shall not exceed 6-in (measured before compaction) when hand operated equipment is used.

C. Fill and backfill shall not be placed and compacted when the materials are too wet to

properly compact (i.e. the in-place moisture content of the soil at that time is no more than three percentage points above the optimum moisture content of that soil as determined by the laboratory test of the moisture-density relation appropriate to the specified level of compaction).

3.5 FILL AND BACKFILL PROCEDURES

A. Fill and backfill material placed immediately adjacent to and within 10 feet of all structures

shall be select fill. All structure water-tightness tests and damproofing/waterproofing shall be completed prior to placing fill or backfill around structures. Place and compact select fill in even lifts of 8 inches (when loose) uniformly around the structure.

B. Common fill may be used in areas beyond those designated for select fill unless shown or

specified otherwise. Common fill shall be placed in even lifts having a maximum thickness (measured before compaction) of 12 inches.

C. Fill required beneath building slabs or slabs on grade (except sidewalks) shall be

structural fill. Place and compact structural fill in even lifts of 8 inches (when loose). 3.6 IMPERVIOUS FILL

A. Impervious fill shall be placed in controlled, even lifts having a maximum thickness

(measured before compaction) of 6 inches. Compaction shall be sufficient to attain a permeability of less than 1x10-7 cm/sec.

B. Moisture content of impervious fill to be compacted shall be maintained at or near its

optimum moisture content (at or within 2 percent of the optimum as determined from ASTM D 1557-00.).

3.7 COMPACTION REQUIREMENTS

A. 10 feet around structures: Compact the top 12 inches of existing subgrade and each layer

of fill or backfill to a minimum of 92 percent modified proctor (ASTM D1557) at or near its optimum moisture content (at or within 2 percent of the optimum as determined from ASTM D 1557-00.)

Bid Set April 2017

Earthwork 02200-7


B. Embankments (except under roadways), lawn or unimproved areas: Compact the top 6 inches of existing subgrade and each layer of fill or backfill to a minimum of 85 percent standard proctor (ASTM D698) at or near its optimum moisture content (minus 1 to plus 4 percent).

C. Beneath building slabs and slabs on grade (except sidewalks): Compact the top 12

inches of existing subgrade (and each layer of fill if applicable) to a minimum of 95 percent modified proctor (ASTM D1557) at or near its optimum moisture content (at or within 2 percent of the optimum as determined from ASTM D 1557-00.).

D. Sidewalks: Compact the top 6 inches of existing subgrade (and each 6-inch layer of fill if

applicable) to a minimum of 95 percent modified proctor (ASTM D1557) at or near its optimum moisture content (at or within 2 percent of the optimum as determined from ASTM D 1557-00.).

E. Roads, paved areas and roadway embankments: Compact the top 12 inches of existing

subgrade and each layer of fill or backfill to a minimum of 95 percent modified proctor (ASTM D1557) at or near its optimum moisture content (at or within 2 percent of the optimum as determined from ASTM D 1557-00.).

3.8 DISPOSAL OF UNSUITABLE, WASTE AND/OR SURPLUS EXCAVATED MATERIAL

A. Unsuitable, waste and surplus excavated material shall be removed and disposed of off-

site. Materials may be temporarily stockpiled in an area within the limits of construction that does not disrupt construction activities, create any nuisances or safety hazards, or otherwise restrict access to the work site.

3.9 GRADING

A. Grading shall be performed to the lines and grades shown on the Drawings. All

objectionable or unsuitable material encountered within the limits indicated shall be removed and disposed of. Subgrades shall be completely and continuously drained and dewatered throughout the grading process. Install temporary drains, drainage ditches, etc, to intercept or divert surface water, which may affect the execution or condition of grading work.

B. If at the time of grading it is not possible to place any material in its proper section of the

Work, it shall be stockpiled in approved areas for later use. No extra payment will be made for the stockpiling or double handling of excavated material.

C. Stones or rock fragments larger than 4-in in their greatest dimensions will not be

permitted within the top 12-in of the finished grade of fills and embankments.

D. In cut areas, all loose or protruding rocks in slopes shall be removed to line or finished grade of the slope. All cut and fill slopes shall be uniformly dressed to the slope, cross-section and alignment shown on the Drawings unless otherwise directed by the Engineer.

Bid Set April 2017

Earthwork 02200-8


3.10 SUBGRADE PREPARATION FOR SLAB ON GRADE

A. Areas under the footprint of slabs on grade excavated to remove existing site structures, or to construct other components of the project (footings, tanks, pipe trenches, etc.), shall have the native grade removed per 3.10B and then the exposed subgrade scarified six inches deep and re-compacted to 95 percent of maximum density as determined by ASTM D1557 method D. The excavated area shall be backfilled with layers of compacted structural fill placed and compacted in accordance with the provisions of Paragraph 3.07.

B. The top 12 inches below the final subgrade level of the footprint shall be over-excavated

and replaced in two 6-inch layers compacted to 95 percent relative density at 110 percent of optimum moisture content.

C. Place a 4-inch layer of compacted crushed rock on top of the compacted structural fill or

recompacted subgrade areas and cover with 10 mil Visqueen followed by a two-inch layer of sand meeting the grading requirements specified in Section 02230. The crushed rock shall not be placed on improperly prepared structural fill.

D. The crushed rock shall be compacted to a minimum of 95 percent of maximum relative

density as determined by ASTM D1557.

E. The placement and compaction of the crushed rock and sand shall be performed so that the top of the material provides a firm horizontal surface against which the structural concrete will be placed.

F. Dampen the sand layer just prior to the placement of concrete to maintain adequate

water for hydration of the cement. 3.11 EQUIPMENT

A. Equipment must be maintained in proper tune to reduce emissions.

END OF SECTION

Bid Set April 2017

Trenching, Backfilling and Compaction 02221-1


SECTION 02221

TRENCHING, BACKFILLING AND COMPACTION


A. Furnish all labor, materials, equipment and incidentals necessary to perform all trenching for

pipelines and appurtenances, including drainage, filling, backfilling, disposal of surplus material and restoration of trench surfaces and easements.

B. Excavation shall extend to the width and depth shown on the Drawings or as specified

and shall provide suitable room for installing pipe, structures and appurtenances.

C. The Contractor shall furnish and place all sheeting, bracing and supports and shall remove from the excavation all materials which the Engineer may deem unsuitable for backfilling. The bottom of the excavation shall be firm, dry and in all respects, acceptable. If conditions warrant, the Contractor may be ordered to deposit gravel for pipe bedding, or gravel refill for excavation below grade, directly on the bottom of the trench immediately after excavation has reached the proper depth and before the bottom of the trench has become softened or disturbed by any cause whatever. The length of open trench shall be related closely to the rate of pipe laying. All excavation shall be made in open trenches.

D. All excavation, trenching, and related sheeting, bracing, etc. shall comply with the

requirements of OSHA excavation safety standards (29 CFR Part 1926.650 Subpart P) and State requirements. Where conflict between OSHA and State regulations exists, the more stringent requirements shall apply.

E. Wherever the requirement for "90 percent" compaction is referred to herein it shall mean "at

least 90 percent of maximum density as determined by ASTM D1557, Method D".

F. Prior to the start of work, the Contractor is required to submit his proposed method of backfilling and compaction to the Engineer for review.

1.2 RELATED WORK

A. Structural earthwork is included in Section 02200.

B Granular fill materials is included in Section 02230.

C. Asphalt Concrete Pavement is included in Section 02500.

D. Dust control is included in Section 01562.

1.3 SUBMITTALS

A. Submit to the Engineer at the preconstruction conference, excavation plans signed with a

"wet" signature and stamped on each submittal drawing by a registered civil or structural

Bid Set April 2017



engineer for worker protection required by Labor Code Section 6705 for any trench 5 feet or more in depth in accordance with the requirements of Section 01300. See Paragraph 3.03 herein for other requirements.

PART 2 PRODUCTS – NOT USED

PART 3 EXECUTION 3.1 TRENCH EXCAVATION

A. Trench excavation shall include material of every description and of whatever substance

encountered, except rock and boulders. Pavement shall be cut with a saw, wheel or pneumatic chisel along straight lines before excavating.

B. The Contractor shall strip and stockpile topsoil from grassed areas (if any) crossed by

trenches. At the Contractor's option, topsoil may be otherwise disposed of and replaced, when required, with approved topsoil of equal quality.

C. While excavating and backfilling is in progress, traffic shall be maintained, and all utilities

and other property protected as provided in the General Conditions and General Requirements.

D. Trenches shall be excavated to the depth indicated on the Drawings and in widths sufficient

for laying the pipe, bracing and for pumping and drainage facilities. The bottom of the excavations shall be firm and dry and in all respects acceptable to the Engineer. Trench width shall be practical minimum or as shown on the drawings.

E. Excavation and dewatering shall be accomplished by methods which preserve the

undisturbed state of subgrade soils. The trench may be excavated by machinery to, or just below the designated subgrade, provided that material remaining in the bottom of the trench is no more than slightly disturbed. Subgrade soils, which become soft, loose, "quick", or otherwise unsatisfactory as a result of inadequate excavation, dewatering or other construction methods shall be removed and replaced by screened gravel fill as required by the Engineer at the Contractor's expense.

F. Clay and organic silt soils are particularly susceptible to disturbance due to construction

operations. When excavation is to end in such soils, the Contractor shall use a smooth-edge bucket to excavate the last one-foot of depth.

G. Where pipe is to be laid in screened gravel bedding, the trench may be excavated by

machinery to the normal depth of the pipe provided that the material remaining in the bottom of the trench is no more than slightly disturbed.

H. Where pipe is to be laid directly on the trench bottom, final excavation at the bottom of the

trench shall be performed very carefully with mechanical equipment to provide a flat-bottom true to grade upon undisturbed material. Additional manual excavation may be required if a suitable foundation cannot be achieved with mechanical equipment. Bell holes shall be made as required.

I. Temporary Paving/Limits of Excavation: Except by expressed written permission of the

Bid Set April 2017



Engineer, the maximum length of open trench shall be 600 feet, or the distance necessary to accommodate the amount of pipe installed in a single day, whichever is the greater. The distance is the collective length at any location, including open excavation, pipe laying and appurtenances, and backfill, which has not been temporarily resurfaced with a leveling asphaltic pavement course.

J. At the end of each day all open trenches within paved streets shall be backfilled or steel

plated with decking and adequate trench bracing to facilitate the next day's work unless otherwise required by governmental permit. The open trench with decking shall be limited to exposure of the pipe end of the last length of pipe installed. No other open trenches shall be allowed at the end of each workday, except by written permission of the Engineer.

3.2 DISPOSAL OF MATERIALS

A. Excavated material shall be stacked without excessive surcharge on the trench bank or

obstructing surface drainage and free access to hydrants and gate valves. Inconvenience to traffic and abutters shall be avoided as much as possible. Excavated material shall be segregated for use in backfilling as specified below.

B. The Contractor shall make the necessary arrangements for, and shall remove and

dispose of all excess excavated material. All costs for the disposal of excess of waste material shall be borne by the Contractor.

It is the intent of these Specifications that all surplus material from the combined phases of the project not required for backfill or fill shall be disposed of by the Contractor outside the limits of the public rights-of-way and/or easements at no cost or liability to the Owner unless approved in writing by the Engineer.

No excavated material shall be deposited on private property unless written permission from the owner thereof is secured by the Contractor. Before the Owner will accept the work as being completed, the Contract shall file a written release signed by all property owners with whom he has entered into agreements for disposal of excess excavated material absolving the Owner from any liability connected therewith.

C. Should conditions make it impracticable or unsafe to stack material adjacent to the trench,

the material shall be hauled and stored at a location provided by the Contractor. When required, it shall be re-handled and used in backfilling the trench.

3.3 SHEETING AND BRACING

A. Furnish, put in place and maintain sheeting and bracing required by Federal, State or local

safety requirements to support the sides of the excavation and prevent loss of ground which could endanger personnel, damage or delay the work or endanger adjacent structures. If the Engineer is of the opinion that at any point sufficient or proper supports have not been provided, he/she may order additional supports placed at the expense of the Contractor. Compliance with such order shall not relieve the Contractor from his/her responsibility for the sufficiency of such supports. Care shall be taken to prevent voids outside of the sheeting, but if voids are formed, they shall be immediately filled and rammed.

Bid Set April 2017



B. Where sheeting and bracing is required to support the sides of trenches, the Contractor shall engage a Professional Engineer, registered in the State of California, to design the sheeting and bracing. The sheeting and bracing installed shall be in conformity with the design and certification of this shall be provided by the Professional Engineer. Contractor shall submit P.E. Certification Form contained in Section 01300 to show compliance with this requirement.

C. When moveable trench bracing such as trench boxes, moveable sheeting, shoring or

plates are used to support the sides of the trench, care shall be taken in placing and moving the boxes or supporting bracing to prevent movement of the pipe, or disturbance of the pipe bedding and the pipe zone material.

1. When installing rigid pipe (R.C., V.C., A.C. etc.), any portion of the box extending

below mid diameter shall be raised above this point prior to moving the box ahead to install the next pipe. This is to prevent the separation of installed pipe joints due to movement of the box.

2. When installing flexible pipe (PVC, D.I., etc.) trench boxes, moveable sheeting,

shoring or plates shall not be allowed to extend below mid-diameter of the pipe. As trench boxes, moveable sheeting, shoring or plates are moved, pipe zone material shall be placed to fill any voids created and the pipe zone material and backfill shall be recompacted to provide uniform side support for the pipe.

D. The Contractor will be permitted to use steel sheeting in lieu of wood sheeting for the entire

job wherever the use of sheeting is necessary. The cost for use of sheeting will be included in the bid items for pipe and shall include full compensation for driving, bracing and later removal of sheeting.

E. All sheeting and bracing shall be carefully removed in such manner as not to endanger the

construction of other structures, utilities, or property, whether public or private. All voids left after withdrawal of sheeting shall be immediately refilled with sand by ramming with tools especially adapted to that purpose, by watering or otherwise as directed.

F. Sheeting driven below mid-diameter of any pipe shall remain in place from the driven

elevation to at least 1-ft above the top of the pipe. 3.5 EXCAVATION BELOW GRADE AND REFILL

A. Whatever the nature of unstable material encountered or the groundwater conditions,

trench drainage shall be complete and effective.

B. If the Contractor excavates below grade through error or for his own convenience, or through failure to properly dewater the trench, or disturbs the subgrade before dewatering is sufficiently complete, he may be directed by the Engineer to excavate below grade as set forth in the following paragraph, in which case the work of excavating below grade and furnishing and placing the crushed rock refill (imported sand or suitable native material) shall be performed at his own expense.

C. If the material at the level of trench bottom consists of fine sand, sand and silt or soft earth

which may work into the pipe zone material notwithstanding effective drainage, the subgrade material shall be removed to the extent directed and the excavation refilled with

Bid Set April 2017



a 6-in layer of coarse sand, or a mixture graded from coarse sand to the fine peastone, as approved by the Engineer, to form a filter layer preserving the voids in the pipe zone material of the pipe. The composition and gradation of gravel shall be approved by the Engineer prior to placement. Pipe zone material shall then be placed in 6-in. layers thoroughly compacted up to the normal grade of the pipe.

D. Geotextile filter fabric may be substituted for filter layer if approved by the Engineer.

Filter fabric shall be Mirafi 140NS, Supac equivalent, or equal.

E. Where the trench bottom has been excavated below grade, a layer of rock foundation material, imported sand as specified in Section 02230 or suitable native material shall be placed to bring the bottom of the excavation to grade.

F. No compacting shall be done when either the previously placed or the new materials are

too wet to obtain the compaction specified. At such times, the materials shall be removed and replaced with suitable material for compacting as specified or work shall be suspended until the previously placed and new materials have dried sufficiently to permit proper compacting.

3.6 TRENCH BACKFILL REQUIREMENTS

A. All trench backfill should consist of approved earth materials free of trash or debris,

vegetation or other deleterious matter. Where in-place foundation soils have adequate permeability to allow rapid infiltration of water, or adequate drainage is provided by other means by the Contractor, as approved by the Engineer, then granular backfill soils can be consolidated by flooding and use of vibrator compactors. If, in the opinion of the Engineer, adequate drainage in the trench is not available, mechanical compaction shall be required. See the geotechnical report for compaction recommendations.

The Contractor may sluice the backfill material to obtain the required compaction provided there is, in the Engineer's opinion, adequate natural drainage or if the Contractor provides adequate drainage by other means and as approved by the Engineer. See the geotechnical report for backfilling recommendations.

B. If rolling is employed, it shall be by use of a suitable roller or tractor, being careful to

compact the fill throughout the full width of the trench. Where other methods are not practicable, compaction shall be by use of hand or pneumatic ramming with tools weighing at least 20 lbs. The method shall consist of one man ramming for each man shoveling backfill into trench, the material being spread and compacted in layers not over 8 inch thick. If necessary, sprinkling shall be employed in conjunction with rolling or ramming. If backfilling is done by machine, it shall be conducted in a manner to obtain results equal to those obtained by other methods described above. No pneumatic ramming tools shall be used to compact backfill for PVC, fiberglass or asbestos - cement pipe.

C. Fill should be spread in thin horizontal lifts, moisture conditioned and compacted to the

specified minimum density. The fill should be placed and compacted on each side of the pipe simultaneously to avoid unbalanced loads.

D. The excavated native material may be used for backfilling in the zones specified herein.

Unless otherwise specified, fragments greater than three (3) inches in dimension shall be

Bid Set April 2017



excluded from all backfill.

E. Bituminous paving fragments shall not be placed in backfilling. Frozen material shall not be used under any circumstances.

F. All roads, outside the Contractor's work area, shall be in a drivable condition for through-

traffic at all times.

G. All road surfaces shall be broomed and hose-cleaned immediately after backfilling. 3.7 PLACEMENT OF PIPE BEDDING WITHIN THE PIPE ZONE

A. Pipe zone backfill including the full width of the trench extending from one-eighth the inside

pipe diameter or a minimum of 4-inches, whichever is greater, below the outside of the pipe to a minimum horizontal level twelve (12) inches above the top of the pipe. The pipe zone shall contain no cinders or other material, which may cause pipe corrosion.

Imported sand backfill or crushed rock meeting the requirements of Pipe zone material as specified in Section 02230 shall be used for pipe zone backfill. Although some of the cleaner on-site sands may be satisfactory, is should be anticipated that import material will be required for pipe zone backfill. Pipe zone material should have no rocks greater than two inches in diameter.

B. The pipe zone material shall be placed as shown on the Drawing, Typical Trench Detail.

Pipe zone material shall be spread and the surface graded to provide a uniform and continuous support beneath the pipe at all points between bell holes or pipe joints. It will be permissible to slightly disturb the finished subgrade surface by withdrawal of pipe slings or other lifting tackle.

C. After each pipe has been graded, aligned, and placed in final position on the bedding

material and shoved home, sufficient pipe zone material shall be deposited and compacted under and around each side of the pipe and back of the bell or end thereof to hold the pipe in proper position and alignment during subsequent pipe jointing and bedding operations.

D. Pipe zone material shall then be deposited and compacted uniformly and simultaneously on

each side of the pipe to prevent lateral displacement and to fill all spaces beneath the pipe. Pipe zone material shall be compacted to a minimum 90 percent of ASTM D-1557 maximum dry density.

E. All work within public right-of-way shall be compacted to a minimum 90 percent of ASTM D-

1557 maximum dry density per Section 306-1.03 of the SSPWC latest edition and Brown Book modifications.

3.8 BACKFILLING ABOVE THE PIPE ZONE

A. Wherever a grass sod, landscaped, or gravel surface exists prior to excavations, it shall be

removed, conserved, and replaced to the full original depth. In some areas, it may be necessary to remove excess material during the clean-up process, so that the ground may be restored to its original level and condition. If the Contractor prefers not to store topsoil he shall replace it with topsoil of equal quality and in equal quantity. Gravel

Bid Set April 2017



surfaces shall be replaced to their original depth or 6 inches, whichever is greater.

B. Where the new work is installed in an existing street, a proposed future street, within railroad right-of-way, or under concrete flatwork, the trench above the pipe zone, from 12 inches above the top of the pipe up to a depth of twelve (12) inches below the bottom of the specified permanent road base and asphaltic concrete pavement section or gravel road base shall be backfilled with common fill material. Backfill shall be compacted in maximum 8 inch lifts to a minimum of 90 percent of ASTM D-1557 maximum dry density. Particles in excess of 3-inches in dimension should be excluded from the fill above the pipe zone.

The remainder of the trench, from 12 inches below the pavement section to the bottom of the specified permanent road base and asphaltic concrete pavement section or gravel road base shall be defined as street zone backfill, and shall be backfilled with select common fill material. Backfill in this zone shall be compacted in maximum 8 inch lifts to a minimum of 95 percent of ASTM D-1557 maximum dry density.

C. Where the new work is installed under open fields or landscaped areas, the remainder of the

trench from 12 inches above the top of the pipe to the existing ground surface shall be backfilled with common fill placed in maximum 8-inch-loose layers compacted to at least 85% of ASTM D-1557 maximum dry density. The trench surface shall be completed as shown on the Drawing Details.

D. At the Contractor's option, imported sand backfill can be installed in lieu of select

common fill and common fill. No extra compensation shall be made to the Contractor.

3.9 RESTORING TRENCH SURFACE

A. Where the trench occurs adjacent to paved streets, in shoulders, sidewalks, or in cross-country areas, the Contractor shall thoroughly consolidate the backfill and shall maintain the surface as the work progresses. If settlement takes place, he shall immediately deposit additional fill to restore the level of the ground.

B. The surface of any driveway or any other area which is disturbed by the trench excavation

and which is not a part of the paved road shall be restored by the Contractor to a condition at least equal to that existing before work began.

C. In sections where the pipeline passes through grassed or landscaped areas, the

Contractor shall, at his own expense, remove and replace the topsoil, and re-landscape the area with equivalent topsoil and plants to the satisfaction of the Engineer.

3.10 PROTECTION

A. Concrete curbing, sidewalks, guardrails, traffic signs, mailboxes, fencing, and other facilities

in the vicinity of the Contractor's operations shall be adequately protected and, if necessary, removed and restored in kind after backfilling. All curbing, sidewalks, guardrails, traffic signs, utility boxes, mailboxes, fencing, and other facilities which are damaged during construction shall be replaced with material fully equal to that existing prior to construction.

END OF SECTION

Bid Set April 2017




Bid Set April 2017

Granular Fill Materials 02230-1


SECTION 02230

GRANULAR FILL MATERIALS

PART 1 GENERAL 1.1 DESCRIPTION

A. Granular fill materials are specified in this Section, but their use for bedding pipe,

replacement of unsuitable material, pavement base, foundation support and similar uses are specified in detail elsewhere. The Engineer may order the use of fill materials for purposes other than those specified in other Sections if, in his opinion, such use is advisable.

1.2 RELATED WORK

A. Earthwork is included in Section 02200.

B. Pipe backfill requirements are included in Section 02221.

PART 2 PRODUCTS

2.1 MATERIALS

A. Pipe zone material shall be imported sand backfill (or native, on-site sand material)

consisting of clean, hard, durable uncoated particle sand, essentially free from frost, frozen lumps, alkali, soft or flaky materials, loam and clay. It shall be well graded having a sand equivalent in excess of thirty (30) and, an expansion index of less than thirty (30). The grading of sizes and material shall be such that the sand may be thoroughly consolidated. The grading shall conform to the following requirements:

Sieve Percent Passing

3/8 inch 100 No. 4 75-100 No. 30 12-50 No. 100 5-20 No. 200 0-15

B. Crushed rock or rock refill shall consist of hard, durable, particles of proper size and

gradation, free from sand, loam, clay, excess fines and deleterious materials. The size of the particles shall be uniformly graded gravel as follows:

Sieve Percent Passing

2 inches 100 1 inch 70-100 3/4 inch 60-100 No. 4 25-55 No. 30 10-30 No. 200 0-10

Bid Set April 2017

Granular Fill Materials 02230-2


C. Common fill shall consist of onsite, excavated soil, substantially free of clay, organic material, loam, wood, trash, and other objectionable material which may be compressible, or which cannot be compacted properly. Common fill shall not contain material larger than 3-in. in any dimension, except as permitted in Section 02200 for material placed more than eight feet below foundation grade. It shall have physical properties, as approved by the Engineer, such that it can be readily spread and compacted.

D. Select common fill or structural fill shall be as specified above for common fill except that the

fill shall contain no material larger than two inches in its largest dimension, except as permitted in Section 02200 for material placed more than eight feet below foundation grade.

E. Aggregates for road base course under pavement shall comply with Class II aggregate

base in accordance with the latest edition of Caltrans standard specifications. The minimum R-value shall be 78, the minimum sand equivalent shall be 30 and the minimum durability index of 35.

F Imported 3/4-inch slag utilized in open areas for erosion and weed control shall be Base

Class II (21-S) slag as supplied by Heckett Slag (714) 822-4480 or equal. PART 3 EXECUTION

3.01 INSTALLATION

A Granular bedding material or imported sand backfill shall be placed on firm, solid, well-

compacted foundation and shall be placed to the depths specified or shown on the Drawings.

B Crushed rock foundation and/or sand shall be utilized and placed in areas as shown on the

Drawings, as specified, and as may be directed by the Engineer.

C Common fill and select fill shall be utilized and placed in areas as shown on the Drawings, as specified, and as may be directed by the Engineer. Where on-site materials cannot be used for common fill or select common fill, the Contractor shall use imported sand backfill. No additional compensation will be made for imported sand backfill placed within the pipe trench limits as shown on the Drawings.

END OF SECTION

Bid Set April 2017

Excavation Support and Protection 02311-1


SECTION 02311 EXCAVATION SUPPORT AND PROTECTION

PART 1 GENERAL

1.1 SCOPE OF WORK

A. The work specified in this Section includes requirements for excavation and support of temporary excavations, and trenches. The Contractor shall design, furnish, install, and maintain a system of supports, including all bracing and associated items, to retain excavations in a safe manner and to control ground movements. Upon completion of the required construction the system of supports shall be completely removed and the excavation and staging area sites restored as discussed herein.

B. The work shall include site grading; fencing and signing; construction staging areas; design and construction of excavation support systems; [design and construction of thrust blocks]; disposal of excavated material, surface water, and ground water; backfilling; and site restoration. Work shall include all labor, materials, and equipment required to complete excavation support.

C. Retain the services of a professional engineer registered in the State in which the work will occur to prepare excavation support and protection system designs and submittals described herein.

D. Work shall include the design, equipment, materials, installation, protection, and monitoring of geotechnical instrumentation required to monitor the performance of the excavation support system as required herein.

E. All excavations and support systems shall conform to applicable OSHA excavation, trenching, and shoring standards which are contained in the U.S. Code of Federal Regulations 29 (C.F.R.) 1926.650-1926.653, other federal, state or local requirements. In the event of a conflict, comply with the more restrictive applicable requirements.

1.2 RELATED WORK

A. Testing and Laboratory Services is included in Section 01410.

B. Site Preparation is included in Section 02100.

C. Earthwork is included in Section 02200.

D. Trenching, Backfilling and Compaction is included in Section 02221.

E. Granular Fill Materials are included in Section 02230.

1.3 SUBMITTALS

A. Submit to the Engineer in accordance with Section 01300, Shop Drawings and design calculations for the Contractor-designed excavation support system stamped by a

Bid Set April 2017



Professional Engineer in the State of California. Submittals shall indicate the following, as a minimum:

B. Shop Drawings shall include:

1. Provide overall plan layout of the system, indicating clearances, dimensions, material properties, member sizes, locations, spacing and penetrations depth of all members, locations of various types of lateral supports. Indicate existing and proposed utilities, structures or other obstruction, location and type of instrumentation and monitoring points within the area of influence of the excavation.

2. Provide wall elevations and locations of all bracing.

3. Show the overall sequence of installation and removal of bracing, indicating levels to which the work will be carried out before bracing is installed or removed.

4. Method of preloading bracing (if required) and the preload for each member, and the method of locking-off the preload. Include detailed drawings of the connections, jacking supports and method of shimming.

5. Details, layout, arrangement, equipment requirements, and method of construction of the proposed excavation support system.

6. Procedures for resolving difficulties arising from misalignment of members exposed during excavation, and criteria for implementing those procedures.

C. Design calculations shall include:

1. Loads on the excavation support system for all stages of excavation, bracing removal, and concrete placement, including material and equipment loads on adjacent ground during construction.

2. Design of wall and all bracing members including all details for all stages of construction. [Design shall account for water pressures associated with flood conditions.]

3. Theoretical deflections of excavation support system and deformation of structures, pipelines, and other improvements located within the area of influence of the excavation.

D. Submit quality control measures as required to ensure that the performance of the excavation support system is consistent with the approved shop drawings and the requirements herein.

E. Submit welder qualifications and weld procedures in accordance with AWS D1.1.

F. Submit Contractor's and Design Engineer's qualifications as described in herein

G. At least one copy of the design shall be maintained at the job site during excavation that includes a plan indicating the sizes, types, and configurations of the materials to

Bid Set April 2017



be used in the protective system, and the identity of the registered engineer who approved the design.

H. Do not proceed with any support of excavation or protection activities until the submittal has been accepted by the Owner and the Engineer.

I. Design Engineer's documentation shall include:

1. On-site inspections of excavation support system as the systems are constructed.

2. Review of quality control measures and performance data.

3. Certification that the excavation support system is constructed per the applicable design following completion of each support system and following any modifications by Contractor during construction.]


A. Regulations: Perform all work in accordance with current applicable regulations and codes of all Federal, State and local agencies.

B. The Contractor shall have at least 5 years of experience with work compatible to the Work shown and specified, employing labor and supervisory personnel who are similarly experienced in this type of Work.

C. The Contractor's Design Engineer shall be a Registered Professional Structural Engineer in the State in which the work is located with at least 5 years of professional experience in the design and construction of support of excavation systems and shall have completed not less than 5 successful excavation support projects of equal type, size, and complexity to that require for the work.

1.5 DESIGN REQUIREMENTS

A. The design of temporary excavation support systems is the responsibility of the Contractor. The design calculations and drawings shall be prepared, stamped and signed by a Professional Structural Engineer registered in the State of California who is experienced in designing similar excavation support systems.

B. Design temporary excavation support systems in accordance with requirements of this Section. These criteria are the minimum acceptable standards.

C. All underground utility lines shall be identified, located, and protected from damage or displacement. Utility companies and other responsible authorities shall be contacted to locate and mark the locations and, if they so desire, direct or assist with protecting the underground installation. When required, the Contractor shall obtain an excavation permit from the local authority having jurisdiction prior to the initiation of any excavation work.

D. Design excavation support systems in accordance with all OSHA requirements and

other local and agency requirements.

Bid Set April 2017



E. Design the support system to minimize horizontal and vertical movements and to protect adjacent structures and utilities from damage.

F. Excavations below the level of the base of any adjacent foundation or retaining wall shall not be permitted unless the design of the excavation and bracing includes an analysis of the stability of the structure supported by the foundation and as necessary, incorporates required bracing/underpinning of the foundation.

G. For support systems in which bracing is installed between opposite sides of the excavation, design the excavation support of both sides to be nearly the same as feasible.

H. Where necessary to resist point loads, pipe piles used as soldier piles shall be filled with concrete with a compressive strength not less than 3,000 psi. The strength of the concrete shall not be considered in design of the pipe pile for bending stress.

I. Design review and field monitoring activities by the Owner or by the Engineer shall not relieve the Contractor of his/her responsibilities for the work.

PART 2 PRODUCTS

2.1 MATERIALS

A. Soldier piles and structural steel members shall conform to ASTM A572 or ASTM A242 unless approved otherwise. [All steel conforming to ASTM A 572 shall be Grade 345 or better.] No members with permanent deformations are to be provided. Members shall not be spliced unless approved by the Engineer.

B. Pipe piles used as soldier piles shall conform to ASTM A252, Grade 345, or better unless approved otherwise.

C. Steel sheet piling shall conform to ASTM A328 or ASTM A572 or ASTM A690, unless approved otherwise. All steel sheet piling conforming to ASTM A 572 shall be Grade 205 or better.]

D. Liner plates shall be fabricated from structural quality hot-rolled carbon steel sheets or plates conforming to ASTM A1101 with the following minimum properties before cold forming:

E. Plates shall be of either the two- or four-flange type, punched for bolting on all sides. Bolt spacing shall be in accordance with the manufacturer's standard spacing and shall be multiples of the plate length so that the plates having the same curvature shall be interchangeable. Bolt numbers and pattern shall be determined by the liner supplier.

F. Tensile Strength: 42,000 psi

1. Yield strength: 28,000 psi

G. Concrete shall conform to ASTM C33 and ASTM C150 unless otherwise approved.

Bid Set April 2017



H. All timber shall be structural grade with a minimum allowable flexural strength of 1100 psi. Timber lagging shall be at least 3 inches thick and free of large or loose knots.

PART 3 EXECUTION

3.1 GENERAL

A. Commence installation of support system and excavations only after shop drawings have been reviewed and accepted by the Engineer.

B. Methods of construction for excavations shall be such as to ensure the safety of the Work, Contractor's employees, Engineer, and Owner's employees and inspectors, the public and adjacent property and improvements, whether public or private.

C. Before beginning construction at any location of this project, adequately protect existing structures, utilities, trees, shrubs, and other existing facilities. The repair of or compensation for damage to existing facilities shall be at no additional cost to the Owner.

D. As a minimum, place fencing, gates, lights, and signs as necessary around the excavations and staging areas to provide for public safety.

E. Install excavation support systems in accordance with the approved shop drawings and applicable permits.

F. All voids between excavation support system and earth shall be filled with materials acceptable to the Engineer.

G. If unstable material is encountered during excavation, all necessary measures shall be

taken immediately to contain it in place and prevent ground displacement.

H. If settlement or deflections of supports indicate that support system requires modification to prevent excessive movements, redesign and resubmit revised shop drawings and calculations to the Engineer at no additional cost to the Owner.

I. Sufficient quantity of material shall be maintained on site for protection of work and for use in case of accident or emergency.

J. All welding shall conform to the applicable provisions of ANSI/AWS D1.1.

3.2 PORTABLE TRENCH BOXES

A. Portable trench boxes or sliding trench shields may be used for the protection of workers only.

B. Additional excavation, backfilling, and surface restoration required as the result of trench box use shall be at no additional cost to the Owner.

C. Trench boxes or shields shall be designed, constructed, and maintained to meet acceptable engineering and industry standards.

Bid Set April 2017



D. Shields shall be installed in a manner to restrict lateral or other hazardous movement of the shield in the event of the application of sudden lateral loads.

E. A copy of the trench box manufacturer's specifications, recommendations, and limitations shall be in written form and maintained at the job site during all excavation work.

3.3 SOLDIER PILES

A. Install soldier piles with the minimum embedment depths as shown on approved shop drawings.

B. Driven piles shall be installed with driving shoes where hard driving is anticipated.

C. For soldier piles installed in predrilled holes, provide casing or other methods of support as necessary to prevent caving of holes and loss of ground.

D. Predrilled holes for soldier piles shall be backfilled with concrete from the pile tip elevation to the elevation of the bottom of the excavation. The remainder of the predrilled hole shall be backfilled with lean concrete or sand. Concrete strength shall be in accordance with the approved shop drawings.

E. The predrilled hole diameter shall be sufficient to allow for proper alignment and concrete backfilling of the pile.

F. Driven soldier piles shall be advanced without the aid of a water jet

G. Provide timber lagging of sufficient thickness to withstand earth pressures and in accordance with the approved shop drawings.

H. Install lagging such that ground loss does not occur between adjacent or below the lowest board. As excavation proceeds, the maximum height of unlagged face of excavation shall not exceed 4 feet. The unlagged face shall not exceed 2-ft if water seeps or flows from the face of the excavation or if the face of the excavation becomes unstable.

I. As installation progresses, backfill the voids between the excavation face and the lagging. Pack with materials such as hay, burlap, or geotextile filter fabric where necessary to allow drainage of ground water without loss of ground.

3.4 STEEL SHEET PILING

A. Install steel sheet piling with the minimum embedment depths as shown on the approved shop drawings.

B. Drive sheeting in plumb position with each sheet pile interlocked with adjoining piles for its entire length so as to form a continuous diaphragm throughout the length of each run of wall, bearing tightly against original ground. Exercise care in driving so that interlocking members can be extracted without damaging adjacent structures or utilities. The methods of driving, cutting, and splicing shall conform to the approved shop drawings.

Bid Set April 2017



C. Use templates or other temporary alignment facilities to maintain piling line.

D. Prior to installation, the sheet piles shall be thoroughly cleaned and inspected for defects and for proper interlock dimensions. The Contractor shall provide a tool for checking the interlock dimensions.

E. Each sheet pile shall have sufficient clearance in the interlocks to slide, under its own weight, into the interlock of the sheet pile previously placed.

F. Excavation shall not be carried in advance of steel sheet piling installation.

G. Where obstructions are anticipated, pre-excavation or pre-drilling along the sheet pile wall alignment shall be conducted at no additional cost to the Owner. Pre-excavation and pre-drilling shall not extend below the lowest excavation level or into bearing soils for existing or future structures.

H. Obstructions encountered before the specified embedment for piles shall be removed. Where obstructions cannot be removed, the sheet pile system shall be re-evaluated by the Contractor's Design Engineer for the resulted reduced embedment and additional toe stability measure implemented, as required or for realignment of the sheet pile wall. A submittal of the proposed measures shall be provided.

I. Damaged piling or piling with faulty alignment shall be withdrawn and new piling driven properly in its place. The cost of such additional work shall be considered as part of the pile driving and shall be borne by the Contractor.

3.5 LINER PLATES

A. Liner plates shall be installed as soon as excavation has progressed sufficiently for the next ring of plates to be installed. A complete circumferential ring of liner plates shall be installed prior to continuing the excavation. Installing more than one incomplete ring of liner plates at any time is not acceptable. Plates shall be staggered in the vertical direction to facilitate shaft strength and leakage resistance.

B. Liner plates shall be grouted in accordance with the approved shop drawings.

3.6 INTERNAL BRACING

A. Provide internal bracing to carry maximum design load without distortion or buckling.

B. Include web stiffeners, plates, or angles as needed to prevent rotation, crippling, or buckling of connections and points of bearing between structural steel members. Allow for eccentricities caused by field fabrication and assembly.

C. Install and maintain all bracing support members in tight contact with each other and with the surface being supported. Wood shims shall not be used.

D. Coordinate excavation work with installation of bracing. Excavation shall extend no more than 2 feet below any brace level prior to installation of the bracing.

Bid Set April 2017



E. Use procedures that produce uniform loading of bracing member without eccentricities or overstressing and distortion of members of system.

3.7 REMOVAL OF EXCAVATION SUPPORT

A. Do not remove internal bracing and transfer loads to the permanent structure without prior acceptance of the Engineer.

B. Removal shall begin at and progress from the bottom of the excavation. Members shall be released slowly as to note any indication of possible failure of the remaining members or possible cave-in of the sides of the excavation.

C. Backfilling shall progress together with the removal of support systems from excavations.

D. Unless otherwise indicated, remove all portions of excavation support.

E. Do not remove vertical support members that were installed within the zone of influence of new or existing structures. The zone of influence is defined as a zone extending down and away from the outer edge of the structure at 1 horizontal to 1 vertical. Support members installed within this zone shall be cut off at [5] ft below finished grade and abandoned in place.

F. No wood shall remain as part of the abandoned portion of the work.

G. When removing the excavation support system, do not disturb or damage adjacent buildings, structures, waterproofing material, or utilities. Fill voids immediately with lean concrete or well-graded cohesion-less sand, as indicated or as directed by the Engineer.

H. Remove material of the excavation support system from the site immediately.

END OF SECTION

Bid Set April 2017

Controlled Low-Strength Material 02313-1


SECTION 02313 CONTROLLED

LOW-STRENGTH MATERIAL

PART 1 GENERAL

1.1 WORK INCLUDED

This section includes controlled low-strength material (CLSM) used as structural backfill and foundation fill under structures where indicated on the Drawings or required by these Specifications.

Perform all sampling and furnish all testing of materials and products by an independent testing laboratory acceptable to the Engineer but engaged by and at the expense of the Contractor

1.2 RELATED SECTIONS

Section 02200 – Earthwork

Section 03300 – Cast-in-Place Concrete

1.3 SUBMITTALS

Submit to the Engineer, in accordance with the Standard and Special Provisions, submittals including the following:

Proposed supplier and mix design with mix characteristics and compressive strength results.

Air-entraining admixture – Product data including catalogue cut, technical data, storage requirements, product life, recommended dosage, temperature considerations, and conformity to ASTM standards.

Field quality control reports of cylinder breaks and measured slumps within 7 calendar days of each test.

Certifications:

Certify that the Contractor is not associated with the independent testing laboratory, nor does the Contractor or its officers have a beneficial interest in the laboratory.

Certify that admixtures used in the mix design are compatible with each other and the aggregates.


American Concrete Institute (ACI)

ACI 229 – Controlled Low-Strength Materials

Bid Set April 2017



American Society for Testing and Materials (ASTM)

ASTM C33 – Standard Specification for Concrete Aggregates

ASTM C150 – Standard Specification for Portland Cement

ASTM C231 – Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

ASTM C260 – Standard Specification for Air-Entraining Admixtures for Concrete

ASTM C618 - Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM D4832 - Standard Test Method for Preparation and Testing of Controlled Low Strength Material (CLSM) Test Cylinders

ASTM D5971 - Standard Practice for Sampling Freshly Mixed Controlled Low-Strength Material

ASTM D6023 - Standard Test Method for Density (Unit Weight), Yield, Cement Content, and Air Content (Gravimetric) of Controlled Low- Strength Material (CLSM)

Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.

1.5 DEFINITIONS

Controlled Low-Strength Material (CLSM) - A self-leveling and self-compacting, cementitious material, sometimes referred to as flowable fill, used as a backfill in place of compacted fill.


Performance Requirements

CLSM shall have a 28-day compressive strength, when tested in accordance with ASTM D4832, from 50 pounds per square inch to a maximum of 150 pounds per square inch. The wet unit weight shall be no greater than 125 pounds per cubic foot.

Consistency shall be flowable and self-leveling, with slump from 6 to 10 inches.

Provide air-entraining admixture and comply with manufacturer’s recommendations.

Bid Set April 2017



CLSM shall be mixed at an off-site concrete plant with adequate equipment to prepare consistent CLSM.


Manufacturer - CLSM shall be manufactured by a ready-mix concrete producer with a minimum of 1 years’ experience in the production of similar products.

Pre-Installation Conference - A pre-installation conference shall be held before the start of field operations to establish procedures to maintain optimum working conditions and to coordinate this work with related and adjacent work. Notify Engineer of the meeting at least 10 days before its scheduled date.

Field Testing - The field-testing of CLSM shall be as specified for concrete in Section 03300.

1.8 DELIVERY, STORAGE, AND HANDLING

Deliver and handle in strict compliance with manufacturer’s recommendations. Protect from damage due to weather, excessive temperatures, and construction operations.

1.9 MEASUREMENT AND PAYMENT

Work shall be considered incidental and compensation shall be included in the Contract prices paid for the various items of work and no additional time or compensation be allowed therefor.

PART 2 PRODUCTS

1.10 GENERAL

The use of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired.

All like materials shall be the products of one manufacturer or supplier in order to provide standardization of appearance.

1.11 MATERIALS

Materials shall comply with this Section and any applicable State or Local requirements.

Cement shall be per Section 03300.

Aggregate shall be per Section 03300, except no aggregate shall be larger than 3/8 inch.

Water shall be per Section 03300.

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Air-Entraining Admixture: The admixture shall comply with ASTM C260. Proportioning and mixing shall be in accordance with the manufacturer’s recommendations. Total air content of the sample prepared in accordance with ASTM C231 shall not exceed 6 percent.

PART 3 EXECUTION

1.12 EXAMINATION

Examine conditions of substrates and other conditions under which work is to be performed and notify Engineer of circumstances detrimental to the proper completion of the work. Do not proceed until unsatisfactory conditions are corrected.

1.13 PLACEMENT

Place CLSM as a structural backfill or foundation fill material where indicated on the Drawings or required by these Specifications.

Place CLSM in a manner so that minimal segregation of the material occurs during and after placement, and without voids. Spade and vibrate as required to consolidate. Monitor placement to prevent flotation of pipes, structures, and other items.

When backfilling retaining walls, place CLSM in lifts to prevent lateral pressures from exceeding the load capacities of the wall.

For each truckload, provide documentation to the Engineer with the following clearly noted: design mix, date, truck number, quantity, and the supplier’s name and address.

1.14 PROTECTION

Protect CLSM from traffic until sufficient strength has been achieved for further construction operations.

END OF SECTION

Bid Set April 2017

Asphaltic Concrete Pavement 02500-1


SECTION 02500 ASPHALTIC

CONCRETE PAVEMENT


A. The Contractor shall furnish all labor, plant and materials necessary to construct all

asphaltic concrete pavement areas, and other works involving asphaltic concrete, in accordance with the latest edition of the CALTRANS standard specifications and as shown on the Drawings and specified herein. References to CALTRANS Standard Specifications refer to the latest edition of the document.

B. Resurfacing of existing concrete flatwork and pavement and surfaces damaged or

removed in connection with the construction of wellhead facilities including pipeline improvements and appurtenances, shall conform to the requirements specified herein and the provisions of permits issued.

C. Measurement and payment for all pavement and concrete flatwork removal and

replacement shall be considered incidental to the contract price and no additional payments shall be made by the Owner to the Contractor.

D. A minimum of 48 hours prior to closing any streets to traffic, the Contractor shall notify the

appropriate City and/or County Fire Departments and Police Departments of the time of closure, and of the streets closed and the approved detour routing.

1.2 RELATED WORK SPECIFIED ELSEWHERE

A. Trenching, backfilling and Compaction is included in Section 02221.

C. Submittals are included in Section 01300.

1.3 SUBMITTALS

A. Shop drawings and product information shall be submitted in accordance with the

requirements of Section 01300 of these Specifications.

B. Road Base

C. Prime Coat

D. Asphalt Mixes 1.4 PRODUCT HANDLING

A. Protection

1. Use all means necessary to protect bituminous concrete pavement materials before,

during and after installation and to protect the installed work and materials of all other trades.

Bid Set April 2017



2. Paving materials delivered to the site prior to placement shall be stockpiled in such a manner as to minimize surface water impact on the stockpile and minimize intrusion of soils adjacent to and beneath the stockpile.

B. Replacements

1. In the event of damage, immediately make all repairs and replacements necessary to

the approval of the Engineer and at no additional cost to the Owner. PART 2 PRODUCTS

2.1 PAVEMENT MATERIALS

A. Road base material shall comply with Class II Aggregate Base in accordance with the

requirements of the CALTRANS Standard Specifications. Class II Base shall have a minimum R-value of 78, a minimum sand equivalent of 30, and a minimum durability index of 35.

B. Prime coat shall be Type SC-70 liquid asphalt conforming to the requirements of the

CALTRANS Standard Specifications.

C. Asphaltic concrete surfacing shall conform to the requirements of the CALTRANS Standard Specifications. Asphaltic concrete surfacing shall be a dense graded mix with a maximum aggregate size of 3/8-inch. Paving asphalt used in the plant-mix shall be stream-refined grade, AR4000 Type B.

PART 3 EXECUTION

3.1 SUBGRADE PREPARATION

A. Scarify minimum 12 inches below subgrade where fill is or pavement is to be placed,

bring to soil moisture content as recommended in Section 02200, and compact to 95 percent of the maximum dry density in accordance with ASTM D-1557. All grading must be complete prior to installing road base or paving.

B. Before the surfacing or pavement is placed, a subgrade shall be constructed conforming to

the grades and cross-sections shown on the Drawings and in accordance with these specifications. The finished subgrade shall be true to grade and cross-sections, hard, uniform, smooth, and shall be compacted at the optimum soil moisture content in 6 to 8-inch lifts, measured prior to compaction, in accordance with CALTRANS Standard Specifications. Compaction shall be in accordance with ASTM D-1557 and Sections 02200 and 02221.

C. The subgrade shall be brought to the proper elevation then sprinkled and rolled with a

steel roller until the subgrade is unyielding.

D. Subgrade for pavement, or other roadway structures shall not vary more than 0.02 foot from the specified grade and cross-section.

Bid Set April 2017



Subgrade for sub-base or base material shall not vary more than 0.04 foot from the specified grade and cross-section. Variations within the above specified tolerances shall be compensated so that the average grade and cross-section specified are met. Subgrade that does not conform to the above requirements shall be watered, recut and thoroughly recompacted.

3.2 ROAD BASE

A. The placing of base shall conform to all applicable portions of the CALTRANS Standard

Specifications except the surface of the finished base at any point shall not vary more than 0.02 foot above or below the grade as shown in the Drawings.

B. Road base, which does not conform to the above requirements, shall be reshaped or

reworked, watered and thoroughly recompacted to conform to the specified requirements.

C. Each layer of road base shall be compacted at the optimum soil moisture content to 95-

percent of the maximum dry density in accordance with ASTM D-1557. 3.3 PRIME COAT

A. Application shall conform to the requirements of the CALTRANS standard specifications.

After completion of the road base, a prime coat of liquid asphalt shall be pressure-spray applied at a rate of approximately 0.25 gallon per square yard, the exact amount and temperature to be determined by the Contractor. In the event an aggregate base is specified; the prime coat shall be applied after completion of the base course. Liquid asphalt shall be prevented from spraying on adjacent ground, structures, curbing, and fencing.

B. If the asphalt concrete pavement is being constructed directly upon an existing hard-

surfaced pavement, a tack coat of either AR 1000 paving asphalt at an approximate rate of 0.05 per square yard or Grade SS-1h emulsified asphalt at an approximate rate of 0.05 to 0.10 gallon per square yard shall be uniformly applied upon the existing pavement preceding the placement of the asphalt concrete. The surface shall be free of water, foreign material, or dust, when the tack coat is applied. To minimize public inconvenience, no greater area shall be treated in any one day than is planned to be covered by asphalt concrete during the same day, unless otherwise authorized by the Engineer.

A similar tack coat shall be applied to the surface of any course, if the surface is such that a satisfactory bond cannot be obtained between it and a succeeding course.

The contact surfaces of all cold pavement joints, curbs, gutters, manholes and the like, shall be painted with either Grade SS-1h emulsified asphalt or AR 1000 paving asphalt immediately before the adjoining asphalt concrete is place.

3.4 ASPHALTIC CONCRETE PAVEMENT

A. The construction of pavements of asphaltic concrete shall conform to the requirements of the

CALTRANS Standard Specifications except, upon completion; the pavement shall be true to grade and cross sections. When a 10-foot straight edge is laid on the finished

Bid Set April 2017



surface parallel to the centerline of the roadway, the surface shall not vary from the edge of the straight edge more than 1/8-inch, except at changes of grade. Any areas that are not within this tolerance shall be brought to grade immediately following the initial rolling. However, if the paving material has been cooled below 260 degrees F, the surface of the pavement shall be brought to a true grade and cross-section by removing the paving material in the area to be repaired, by an approved method, to provide a minimum laying depth of one inch of new pavement material at the joint line. Repairs shall not be made to pavement surfaces by feather-edging at joints.

B. Special attention is directed to the CALTRANS Standard Specifications, which requires

that the minimum weight for rollers utilized for compacting asphaltic concrete pavement shall be eight (8) tons, except as authorized by the Owner for areas that require handwork.

C. A pneumatic-tired roller shall not be permitted for compacting asphaltic concrete.

3.5 ROADWAY SURFACE REMOVAL

A. All pavement sawcuts shall be neat and straight to provide an unfractured and level

pavement joint for bonding existing surfacing with pavement replacement. All cut edges shall provide clean, solid, vertical faces free from all loose material. Where large irregular surfaces are removed, such trimming or cutting as hereinafter provided, shall be parallel or at right angles to the road centerline.

B. All existing crushed aggregate and asphaltic concrete removed shall be hauled away

from the project site and legally disposed of by the Contractor. 3.6 RESURFACING

A. In all existing pavement areas where the surface is removed, broken or damaged by

equipment or in which the ground has caved in or settled due to the installation of the improvements, the surface shall be restored to the original grade by the Contractor. Prior to resurfacing, the existing surfacing shall be removed as provided above. All broken and jagged edges of the pavement edge shall be sawed straight. Areas to be cut shall be indicated by the Owner and no permanent pavement shall be placed until these edges have been sawed. If during the initial removal of the existing pavement a method of removal was used which disturbed the adjoining pavement, or if during general construction operations the adjacent pavement or base material was disturbed, then this adjoining pavement must also be removed and replaced. Where irregular surfaces are to be surfaced, existing pavement shall be cut parallel to the alignment of the pipe or to the centerline of the roadway, at the discretion of the Owner. Asphalt concrete pavement shall be saw cut to a minimum depth of 2-inches at a point not less than 9-inches outside the limits of excavation or the previous pavement cut (made by pneumatic tools), whichever limits are the greater. Where a trench edge is less than four (4) feet from the existing edge of pavement, gutter, or curb, the remaining existing pavement shall be removed and replaced with new base course and pavement. The additional surfacing so cut shall be removed and disposed of by the Contractor prior to resurfacing.

B. Final restoration of asphaltic concrete pavement shall be with an approved plant-mix to a

depth equal to the original depth, plus 1-inch, to a depth as shown on the drawings or to a depth of 3 inches, whichever is greater.

Bid Set April 2017



C. Wherever asphalt cement pavement does not terminate against a curb, gutter, or another pavement, the Contractor shall provide and install a coplastic header. Such headers shall remain in place upon completion of the improvements.

Headers shall be 2-inch (nominal size) boards, the vertical dimension of which shall at least be equal to the thickness of the pavement at the header line. The headers shall have a firm bearing on the header subgrade and the top edges shall be set to conform to the grade of the proposed street surface. Side stakes 2-inches by 3-inches (nominal size), 18-inches long, or longer, and spaced not over 8-feet apart or as indicated on the drawings, shall be driven on the outside of the headers to a depth of 1-inch below the top and then nailed to the header. The joints between the individual boards being used as headers shall be spliced with a 1-inch thick (nominal size) board of the same height as the header and not less than 24-inches long. Headers shall be coplastic.

D. Concrete flatwork and surfaces shall be restored with the following thicknesses of concrete:

Five (5) inches of concrete for driveways; five (5) inches of concrete for streets or match existing thickness whichever is greater; Five (5) inches of concrete for sidewalks in driveway approaches; five (5) inches of concrete for sidewalks not in a driveway approach. Minimum concrete strength shall be 3000 psi or as specified in Division 3.

E. All other surfaces shall be restored to conform in quality and depth with the original

surface within seven days after ordered in writing to do so by the Engineer. 3.7 DETECTORS

The Contractor shall replace all detectors removed or damaged as a part of the work. Cost for equipment and installation shall be included in the Contract prices for the work and no extra compensation will be made to the Contractor.

3.8 PAVEMENT MARKINGS

The Contractor shall reapply all traffic markings removed or damaged by the work. Thermoplastic traffic strips shall conform to the provisions of Section 84 of the CALTRANS Standard Specifications. Replacement of pavement markings shall be included in the Contract prices for the work and no extra compensation will be made to the Contractor.

3.9 TEMPORARY PAVING

A. Temporary paving shall conform to the requirements of Section 306-1.5 of the Standard

Specifications for Public Works Construction. All pavement removed for trenching operations shall be replaced with 2 inches of temporary paving mix after compaction is approved by the Engineer or within three days after the installation of the pipe, whichever comes first.

B. Where the trench limits access to cross streets and drive approaches, the roadway shall be

restored with temporary pavement on the same day that the excavation is made. Temporary pavement will be maintained so that a smooth traversable surface is available at all times for vehicular traffic, free from ruts, depressions, holes, and loose gravel.

Bid Set April 2017



C. Cost for temporary paving shall be included in the Contract prices for the work, and no extra compensation will be made to the Contractor.

3.10 MAINTENANCE OF SURFACE

A. Following the certification of completion by the Owner, the Contractor shall maintain the

surface of the repaved and new pavement areas for a least the period of the guarantee of the Work.

B. All materials and labor required for the maintenance of paving shall be supplied by the Contractor and the Work shall be done in a manner satisfactory to the Owner.

END OF SECTION

Bid Set April 2017

Precast Concrete Manholes and Structures 02605-1


SECTION 02605

PRECAST CONCRETE MANHOLES AND STRUCTURES

PART 1 GENERAL

1.1 SCOPE OF WORK

A Furnish all labor, materials, equipment and incidentals required to install precast concrete manholes, structures, frames and covers, access hatches, ladders, vents and appurtenances all as shown on the Drawings and as specified herein.

1.2 RELATED WORK SPECIFIED ELSEWHERE

A Section 02221, Trenching, Backfilling and Compaction B

Section 02311, Excavation Support and Protection

C. Section 02765, Plastic Lining for Precast Concrete

1.3 SUBMITTALS

A Submit to the Engineer shop drawings, as provided in Section 1300 Submittals, showing details of construction, reinforcing, joints, pipe connection to manhole, manhole frames and covers, access hatches ladders and vents.

B Submit for review, structural calculations and drawings for all precast structures.

C Concrete design mix data and concrete test cylinder reports from an approved concrete testing laboratory certifying that the concrete used in the precast structures conforms with the strength requirements specified herein.



1. ASTM A48 - Standard Specification for Gray Iron Castings

2. ASTM A615 - Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement.

3. ASTM C150 - Standard Specification for Portland Cement.

4. ASTM C207 - Standard Specification for Hydrated Lime for Masonry Purposes.

5. ASTM C443 - Standard Specification for Joints for Circular Concrete Sewer and Culvert Pipe, Using Rubber Gaskets.

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6. ASTM C478 - Standard Specification for Precast Reinforced Concrete Manhole Sections.

7. ASTM D4101 - Standard Specification for Propylene Plastic Injection and Extrusion

Materials.

B. American Concrete Institute (ACI)

1. ACI 318 - Building Code Requirement for Reinforced Concrete.

2. ACI 350R - Environmental Engineering Concrete Structures

C. American Association of State Highway and Transportation Officials (AASHTO)

1. Standard Specifications for Highway Bridges

D. Occupational Safety and Health Administration (OSHA)

E. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.


A. The quality of all materials, the process of manufacture, and the finished sections shall be subject to inspection and approval by the Engineer, or other representative of the Agency. Such inspection may be made at the place of manufacture, or on the work after delivery, or at both places and the materials shall be subject to rejection at any time on account of failure to meet any of the Specification requirements; even though samples may have been accepted as satisfactory at the place of manufacture. Material rejected after delivery to the job shall be marked for identification and shall be removed from the job at once. All materials which have been damaged after delivery will be rejected, and if already installed, shall be acceptably repaired, if permitted, or removed and replaced, entirely at the Contractor's expense.

B. At the time of inspection, the materials will be carefully examined for compliance with the ASTM designation specified below and these Specifications and with the approved manufacturer's drawings. All manhole sections shall be inspected for general appearance, dimension, "scratch-strength", blisters, cracks, roughness, soundness, etc. The surface shall be dense and close-textured.

C. Imperfections in manhole sections may be repaired, subject to the approval of the Engineer, after demonstration by the manufacturer that strong and permanent repairs result. Repairs shall be carefully inspected before final approval. Cement mortar used for repairs shall have a minimum compressive strength of 4,000 psi at 7 days and 5,000 psi at 28 days, when tested in 3-in by 6-in cylinders stored in the standard manner. Epoxy mortar may be utilized for repairs subject to the approval of the Engineer.

Bid Set April 2017



PART 2 PRODUCTS

2.1 PRECAST CONCRETE MANHOLE SECTIONS

A. Precast concrete barrel sections and transition top sections shall conform to ASTM C478 and meet the following requirements:

1. The wall thickness shall not be less than 5-in for 48-in diameter reinforced barrel sections, 6-in for 60-in diameter reinforced barrel sections, and 7-in for 72-in diameter reinforced barrel sections.

2. Barrel sections shall have tongue and groove joints.

3. All sections shall be cured by an approved method and shall not be shipped nor subjected to loading until the concrete compressive strength has attained 3,000 psi and not before five days after fabrication and/or repair, whichever is longer.

4. Precast concrete barrel sections with precast top slabs shall be designed for a minimum of H-20 loading plus the weight of the soil above at 120 pcf.

5. The date of manufacture and the name and trademark of the manufacturer shall be clearly marked on the inside of each precast section.

6. Precast concrete bases shall be constructed and installed as shown on the Drawings. The thickness of the bottom slab of the precast bases shall not be less than the manhole barrel sections or top slab whichever is greater.

7. The manhole base slab, if cast in place as opposed to being furnished as a monolithic component of the precise manhole section, shall be reinforced with Style 6x6 – W5.5 welded wire fabric or equivalent area of reinforcing steel. The base slab, if cast in place, shall be poured so as to ensure a watertight seal at the joint formed by the base slab and riser section.

2.2 PRECAST CONCRETE STRUCTURES

A. The precast reinforced concrete structures shall be manufactured by Associated Concrete Products, Inc., Brooks products, Inc., Jensen Concrete Products, Oldcastle Precast, or equal. The inside dimensions, headroom requirements and minimum thickness of concrete shall be as indicated on the Drawings and as specified herein. The manufacturer shall notify the Engineer at least five working days prior to placing concrete during the manufacturing process. The Engineer may inspect the reinforcing steel placement and/or require the manufacturer to provide photographs of each section showing the location of all reinforcing steel prior to the placing of concrete. Should it be found that the placement of steel is not as detailed in the shop drawing submittals, the section in question shall be rejected and a replacement section shall be manufactured at the Contractor's expense. Failure to properly notify the Engineer prior to placing concrete shall require the precast sections to be rejected and replacement sections to be manufactured at the Contractor's expense.

Bid Set April 2017



B. Structural design calculations and Drawings shall be prepared and stamped by a Professional Engineer registered in the State of California.

C. All precast concrete shall have a minimum compressive strength of 5000 psi at 28 days.

Water shall be kept to a minimum to obtain concrete which is as dense and watertight as possible. The maximum water content shall be 6 gallons per 94 lb sack and the minimum cement factor shall be 6.0 (94 lb) sacks per cubic yard. The above ratios shall be revised for sacks of cement with weight differing from 94 pounds per sack.

D. Design Criteria

1. All precast concrete members shall conform to ACI 318 and ACI 350R.

2. When the design yield strength "fy" for tension reinforcement exceeds 40,000 psi, the "z" values referred to in ACI 318 shall not exceed 95 ksi. The flexural stress in reinforcement under service loads "fs" shall be calculated and shall not be greater than 50 percent of the specified yield strength fy.

3. The precast concrete structure's elements shall be designed to support their own weight, the weight of soil above at 120 pcf and shall be capable of withstanding a live load equal to an AASHTO HS-20 highway loading applied to the top slab.

4. The base slab and walls shall be cast together to form a monolithic base section.

5. All exterior walls shall be designed for an equivalent fluid pressure of 90 lb per sq ft. The top of the pressure diagram shall be assumed to originate at finished ground level. Additional lateral pressure from approaching truck wheels shall be considered in accordance with AASHTO.

6. The structural design shall take into account discontinuities in the structure produced by openings and joints in the structure.

7. All walls and slabs shall be analyzed by accepted engineering principles. Openings shall be completely framed as required to carry the full design loads to support walls. All slabs and walls shall be fully reinforced on both faces and the minimum reinforcing shall be No. 4 at 6-in E.F.E.W. Additional reinforcing shall be provided around all openings.

8. The horizontal wall joints shall not be located within 18-in of the horizontal centerline of wall penetrations.

E. Standard size (6-foot internal diameter) structures shall be built by the manufacturer in no more than three major sections.

F. For the 12-foot diameter vortex manhole, the maximum vertical section length for precast sections shall be 45-inches. Contractor shall coordinate with manufacturer for larger sections that may be needed in order to accommodate and properly install the 42-inch pipe.

Bid Set April 2017



F. As required, access openings and pipe penetrations shall be formed openings and located as shown on the Drawings.

G. Wall sleeves as shown on the Drawings, shall be provided to the precast concrete

manufacturer for inclusion in the manufacture of the structure.

2.3 JOINTING PRECAST MANHOLE SECTIONS AND STRUCTURES

A. Tongue and groove joints of precast manhole and structure sections shall be sealed with either a round rubber "O"-ring gasket or a preformed flexible joint sealant. The "O"-ring shall conform to ASTM C443. The preformed flexible joint sealant shall be Kent Seal No. 2 as manufactured by Hamilton-Kent; Ram-Nek as manufactured by K.T. Snyder Company or equal.

B. Joints shall be designed and manufactured so that the completed joint will withstand an internal water pressure of 15 psi without leakage or displacement of the gasket or sealant.

2.4 PIPE CONNECTIONS TO MANHOLE SECTIONS AND STRUCTURES

A. Manhole pipe connections may be accomplished in the following ways:

1. A tapered hole filled with non-shrink waterproof grout, Hallemite; Waterplug; Embeco or equal, after the pipe is inserted is acceptable, providing the grout is placed carefully to completely fill around the pipe. If this method is used, place concrete encasement to assure a total 12 inches of concrete including wall thickness around the pipe stub.

2. The "Lock Joint Flexible Manhole Sleeve" shall be cast in the precast base. The stainless steel strap shall be protected from corrosion with a bituminous coat.

3. "A-Lok" shall be a rubber like gasket cast in the precast base. The rubber gasket shall be cast into a formed opening in the wall.

4. "KOR-N-SEAL" joint shall be installed as recommended by the manufacturer. The stainless steel clamp shall be protected from corrosion with a bituminous coat.

2.5 DAMPPROOFING

A. The dampproofing shall be Hydrocide 648 by Sonneborn Building Products; Dehydratine 4 by A.C. Horn Inc.; RIW Marine Liquid by Toch Brothers or equal.

2.6 PLASTIC LINER

A. Plastic liner for manholes shall conform to Section 02765 of these Specifications.

Bid Set April 2017



PART 3: EXECUTION

3.1 INSTALLATION

A. Manhole and Structure Installation

1. Manhole and structure shall be constructed to the dimensions shown on the Drawings and as specified in these Specifications. All work shall be protected against flooding and flotation.

2. The bases of manholes and structures shall be placed on undisturbed earth as shown on the Drawings.

3. Precast concrete barrel sections and structures shall be set plumb and with sections in true alignment with a 1/4-inch maximum tolerance to be allowed. The joints of precast barrel sections shall be sealed with either a rubber "O" ring set in a recess or the preformed flexible joint sealant used in sufficient quantity to fill 75 percent of the joint cavity. The outside and inside joint shall be filled with non-shrink mortar and finished flush with the adjoining surfaces. Allow joints to set for 24-hours before backfilling. Backfilling shall be done in a careful manner, bringing the fill up evenly on all sides. If any leaks appear in the manholes, the inside joints shall be caulked with lead wool to the satisfaction of the Engineer. Install the precast sections in a manner that will result in a watertight joint.

4. Holes in the concrete barrel sections required for handling or other purposes shall be plugged with a non-shrinking grout or non-shrinking grout in combination with concrete plugs and finished flush on the inside.

5. Where holes must be cut in the precast sections to accommodate pipes, cutting shall be done prior to setting manhole sections in place to prevent any subsequent jarring which may loosen the mortar joints.

B. Manhole Pipe Connections

1. Manhole pipe connections shall be accomplished in the ways specified hereinbefore. Pipe stubs for future extensions shall also be connected and the stub end closed by a suitable watertight plug.

C. Dampproofing

1. Outer surfaces of precast and cast-in-place manholes and structures shall be given two coats of bituminous dampproofing at the rate of 30-60 sq ft per gallon as directed by the Engineer and in accordance with manufacturer's instructions.

3.2 LEAKAGE TESTS

A. Leakage tests shall be made and observed by the Engineer on each manhole. The test shall be the exfiltration test made as described below:

Bid Set April 2017



B. After the manhole has been assembled in place, all lifting holes and those exterior joints within 6 feet of the ground surface shall be filled and pointed with an approved non-shrinking mortar. The test shall be made prior to placing the shelf and invert and before filling and pointing the horizontal joints below the 6 feet depth line. If the groundwater table has been allowed to rise above the bottom of the manhole, it shall be lowered for the duration of the test. All pipes and other openings into the manhole shall be suitably plugged and the plugs braced to prevent blow out.

C. The manhole shall then be filled with water to the top of the cone section. If the excavation

has not been backfilled and observation indicates no visible leakage, that is, no water visibly moving down the surface of the manhole, the manhole may be considered to be satisfactorily water-tight. If the test, as described above is unsatisfactory as determined by the Engineer, or if the manhole excavation has been backfilled, the test shall be continued. A period of time may be permitted if the Contractor so wishes, to allow for absorption. At the end of this period, the manhole shall be refilled to the top of the cone, if necessary and the measuring time of at least 8 hours begun. At the end of the test period, the manhole shall be refilled to the top of the cone, measuring the volume of water added. This amount shall be extrapolated to a 24-hour rate and the leakage determined on the basis of depth. The leakage for each manhole shall not exceed 1 gallon per vertical foot for a 24-hour period. If the manhole fails this requirement, but the leakage does not exceed 3 gallons per vertical foot per day, repairs by approved methods may be made as directed by the Engineer to bring the leakage within the allowable rate of 1 gallon per foot per day. Leakage due to a defective section or joint or exceeding the 3 gallons per vertical foot per day shall be the cause for the rejection of the manhole. It shall be the Contractor's responsibility to uncover the manhole as necessary and to disassemble, reconstruct or replace it as directed by the Engineer. The manhole shall then be retested and, if satisfactory, interior joints shall be filled and pointed.

D. No adjustment in the leakage allowance will be made for unknown causes such as leaking

plugs, absorptions, etc., i.e. it will be assumed that all loss of water during the test is a result of leaks through the joints or through the concrete. Furthermore, take any steps necessary to assure the Engineer that the water table is below the bottom of the manhole throughout the test.

E. If the groundwater table is above the highest joint in the manhole, and if there is no leakage into the manhole as determined by the Engineer, such a test can be used to evaluate the water-tightness of the manhole. However, if the Engineer is not satisfied, lower the water table and carry out the test as described hereinbefore.

F. Leakage Tests for Structures

1. The Engineer will visually inspect structure(s) for possible leaks before backfilling of structures is allowed. All joints shall be sealed to the satisfaction of the Engineer.

2. The Engineer may require an exfiltration test as described for manholes on any structure for which he/she deems the test appropriate.

Bid Set April 2017



3.3 CLEANING

A. All new manholes and structures shall be thoroughly cleaned of all silt, debris and foreign matter of any kind, prior to final inspection.

END OF SECTION

Bid Set April 2017

Ductile Iron Pipe and Fittings 02616-1


PART 1 GENERAL

1.1 SCOPE OF WORK

SECTION 02616 DUCTILE IRON PIPE AND FITTINGS

A. Furnish all labor, materials, equipment and incidentals required, install, [disinfect] and test ductile iron pipe and fittings for piping as shown on the Drawings and as specified herein.

B. Yard piping shall include all piping and fittings extending outward, upward and downward into the ground from the outside face of all buildings. Unless otherwise noted, non-buried pipe outside a building, including in utility tunnels, shall be specified in Division 15072. Yard piping shall begin at the outside face of the buildings. The first joint shall be not more than 2-feet from the outside face of the building or structure unless otherwise shown on the Drawings. Yard piping shall include all piping in valve vaults, manholes, cleanouts and similar yard structures.]

C. Piping shall be located substantially as shown on the Drawings. The Engineer reserves the right to make such modifications in locations as may be found desirable to avoid interference between pipes or for other reasons. Pipe fitting notation is for the Contractor's convenience and does not relieve him/her from installing and jointing different or additional items were required to achieve a complete piping system.

D. Where the word "pipe" is used, it shall refer to pipe, fittings, or appurtenances unless otherwise noted.

1.2 RELATED WORK

A. Trenching, Backfilling and Compaction is included in Section 02221.

B. Granular Fill Material is included in Section 02230.

C. Piping Specialties are included in Section 15120.

1.3 SUBMITTALS

A. Submit shop drawings and product data, including piping layouts, design calculations, warranty information, test reports, in accordance with PR-9 and the referenced standards.

B. Submit design calculations in accordance with Paragraph 2.02 below signed by a Professional Engineer.

C. Submit the name of the pipe and fitting suppliers and a list of materials to be furnished.

D. Prior to shipment of pipe, certified copies of mill tests confirming the type of materials used in the pipe, and shop testing of pipe to show compliance with the requirements of

Bid Set April 2017



the applicable standards, along with a sworn affidavit of compliance that the pipe complies with the referenced standards, shall be submitted.

E. Submit copies of all shop tests, including hydrostatic tests.

F. Submit information on all warranties per GC-65.

G. Submit shop drawings with a tabulated laying schedule which references stations and invert elevations as shown on the Drawings as well as all fittings, bends, outlets, restrained joints, tees, special deflection bells, adapters, solid sleeves and specials, along with the manufacturer's drawings and specifications providing complete details of all items. The laying schedule shall show pipe class, class coding, station limits and transition stations for various pipe classes. The above shall be submitted to the Engineer for approval before manufacture and shipment. The location of all pipes shall conform to the locations indicated on the Drawings. Full length pipe may be supplied from inventory provided that all specification requirements are met. Shop drawings shall include but not be limited to:

1. Complete and dimensional working drawings of all pipe layouts, including pipe

stationing, invert elevation at changes in grade or horizontal alignment, all elements of curves and bends both in horizontal alignment and vertical position.

2. The grade of material; size, wall thickness, of the pipe and fittings and appurtenances, type and location of fittings, specials, and valves; and the type and limits of the lining, lining reinforcing and coating systems of the pipe and fittings. Methods and procedures recommended by the coating manufacturer will be documented.

3. Joint details; methods and locations of supports and complete information concerning type, size and location of all welds. Shop welds (no field welding will be allowed) will be clearly differentiated and welds will be clearly detailed with preparation procedures for all pipe and parent material comprising each weld. Critical welding procedures will be identified along with methods for controlling welding stresses and distortions. Locations and proposed joint details will also be clearly identified.

4. Method of manufacture of pipe; joint details; fittings; and any specials.

5. All other pertinent information for all items to be furnished; product data to show compliance of all couplings, supports, fittings, coatings and related items.

H. Submit anticipated production and delivery schedule.

I. Prior to shipment of pipe, submit a certified affidavit of compliance from the manufacturer stating that the pipe, fittings, gaskets, linings and exterior coatings for this project have been manufactured and tested in accordance with AWWA and ASTM standards and requirements specified herein.

J. Submit handling procedures for all phases from finished fabrication through delivery including storage, transportation, loading, and unloading. This will include storage at the project site and required protection following installation prior to startup.

Bid Set April 2017




A. ASTM International

1. ASTM A193 - Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service.

2. ASTM A194 - Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-Temperature Service.

3. ASTM A746 - Standard Specification for Ductile Iron Gravity Sewer Pipe.


B. American Water Works Association (AWWA)

1. AWWA C104 - Cement-Mortar Lining for Ductile-Iron Pipe and Fittings for Water.

2. AWWA C105 - Polyethylene Encasement for Ductile-Iron Pipe Systems.

3. AWWA C110 - Ductile-Iron and Gray-Iron Fittings, 3- through 48-inches (75mm Through 1219mm) for Water.

4. AWWA C111 - Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings.

5. AWWA C150 - Thickness Design of Ductile-Iron Pipe.

6. AWWA C151 - Ductile-Iron Pipe, Centrifugally Cast, for Water.

7. AWWA C115 – Flanged Ductile Iron Pipe with Ductile Iron or Grey Iron Threaded Flanges.

8. AWWA C116 – Protective Fusion-Bonded Epoxy Coatings for the Interior and Exterior surfaces of Ductile Iron and Grey Iron Fittings for Water Supply Service.

9. AWWA C153 - Ductile- Iron Compact Fittings, 3- through 24-inches, and 54-inches through 64-inches, for Water.

10. AWWA C550 – Protective Interior Coatings for Valves and Hydrants

11. AWWA C600 - Installation of Ductile-Iron Water Mains and Their Appurtenances.

12. AWWA C606 - Grooved and Shouldered Joints.

C. National Sanitation Foundation (NSF)

1. NSF 61 - Drinking Water System Components Health Effects.

D. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.

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A. It is a requirement of these Contract Documents to have all the ductile iron pipe under thus section designed and supplied by a single manufacturer rather than have selection and supply of these items by several different manufacturers. Similarly, it is a requirement of these Contract Documents to have all the ductile iron fittings under thus section designed and supplied by a single manufacturer rather than have selection and supply of these items by several different manufacturers. All connections between the pipe and fittings shall be compatible, as detailed in Paragraph 1.06.

B. Each length of ductile iron pipe supplied for the project shall be hydrostatically tested at the point of manufacture to 500 psi for a duration of 10 seconds per AWWA C151. Testing may be performed prior to machining bell and spigot. Failure of ductile iron pipe shall be defined as any leak or rupture of the pipe wall. Certified test results shall be furnished in duplicate to the Engineer prior to time of shipment.

C. All ductile-iron pipe and fittings to be installed under this project shall be inspected and tested at the foundry as required by the standard specifications to which the material is manufactured. Furnish in duplicate to the Engineer sworn certificates of such tests and their results at least 5 days prior to the shipment of the goods.

D. Inspection of the pipe and fittings will also be made by the Engineer or representative of the Owner after delivery. The pipe shall be subject to rejection at any time on account of failure to meet any of the Specification requirements even though pipe may have been accepted as satisfactory at the place of manufacture. Pipe rejected after delivery (including defects from manufacturing or delivery/transport) shall be marked for identification and shall immediately be removed from the job at the Contractors expense.

E. All pipe and fittings to be installed under this Contract may be inspected at the plant for compliance with this Section by an independent testing laboratory selected by the Owner at the Owner's expense.

F. A manufacturer's representative shall be made available to the Owner and owner's representative during the manufacturing furnishing, transporting, and unloading of the pipe during installation and testing of the pipe to assist in insuring that the pipe is properly fabricated, transported, unloaded, stored in the field, joined and tested. Manufacturer's responsibilities relate only to the proper care and treatment of the pipe during these procedures and not the techniques or procedures used during installation and testing.

1. The designated factory representative shall be made available at any time the owner may request. The field or site representative shall be made available a minimum of 1 working day (time on site) during the project when requested by the owner.

2. The cost for the services of the factory representative, including expenses, shall be considered incidental to the project and will not be paid separately.

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G. The manufacturer shall meet the following criteria and furnish the necessary project information, which demonstrates the required experience:

1. Experience that includes successful fabrication (followed by installation, acceptance and service) to AWWA C151 standards of at least 50,000 lineal feet of the largest specified diameter or larger ductile iron pipe with similar linings/coatings within the past 5 years.

2. Experience shall include the successful fabrication of at least 50- fittings in compliance with AWWA C110 or C153 of the largest specified diameter or larger with similar lining/coatings within the past 5 years.

3. Experience that includes the successful fabrication (followed by installation, acceptance and service) of at least 10,000 lineal feet of the largest specified diameter or larger push-on style, boltless restrained joint for ductile iron pipe within the last 5 years.

H. All pipe and fittings shall be marked in accordance with all applicable AWWA standards. Legibly and permanently mark all pipe, fittings, specials and appurtenances to be consistent with the laying schedule and marking drawings (if required) with the following information:

1. Manufacturer, date.

2. Size, type, class, or wall thickness.

3. AWWA Standard(s) produced to.

1.6 DESCRIPTION OF SYSTEMS

A. Pipe shall be made in the United States. Fittings may be made outside the United States, but shall be supplied by one of the named pipe manufacturers or engineer approved equal. Pipe and fittings shall be as supplied by the American Cast Iron Pipe Co., United States Pipe and Foundry, Griffin Pipe Products, all pipe divisions of the McWane Company or an approved equal who is a member of the Ductile Iron Pipe Research Association (DIPRA). All ductile iron pipe shall be supplied by a single manufacturer and all ductile iron fittings shall be supplied by a single manufacturer. The fittings supplier shall certify in writing that their fittings are compatible with the supplied brand of pipe.

B. Pipe is to be installed in those locations shown on the Drawings, and only where specifically indicated.

C. Contractor is responsible for compatibility between joints of all items they supply.

D. In the case of conflict between information on the pipe schedule, Drawings, and or this section especially concerning pressures, coatings, linings minimum thickness etc. the information given in the pipe schedule shall govern.

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1.7 DELIVERY, STORAGE AND HANDLING

A. Care shall be taken in loading, transporting, and unloading to prevent injury to the pipe, pipe linings and pipe coatings. See AWWA C600 and the referenced AWWA Standards for Shipping, handling and storage procedures. All pipe and fittings shall be examined as noted in Division 1. Any damage to linings or coatings discovered during the examination shall be repaired to the satisfaction of the Engineer at the cost of the Contractor, before proceeding with the work.

B. Pipe shall be transported to the job site on padded bunks or oak timbers and secured with steel banding or nylon tie down straps to adequately protect the pipe and coating. Slings, hooks, or pipe tongs or other devices acceptable to the Engineer shall be used in pipe handling. No un-cushioned ropes, chairs, wedges, cables or levers shall be used in handling finished pipe, fittings or couplings. Under no circumstances shall the pipe or fittings be dropped or skidded against each other. Care shall be taken to preventing marring the pipe coating. Padded wooden pipe cradles, or chocks suitable for the protection of coatings shall be used between finished pipes and beneath them when pipes are placed upon rough surfaces. Pipe shall not be stored on bare ground unless soft sand berms are used to support the pipe and is approved by the Engineer.

C. Materials, if stored, shall be kept safe from damage. The interior of all pipe, fittings and other appurtenances shall be kept free from dirt, excessive corrosion or foreign matter at all times.

D. Pipe shall not be stacked higher than the limits recommended by its manufacturer. The bottom tier shall be kept off the ground on timbers, rails, or concrete. Stacking shall conform to manufacturer's recommendations and/or AWWA C600.

E. Gaskets for mechanical and push-on joints to be stored shall be placed in a cool location out of direct sunlight. Gaskets shall not come in contact with petroleum products. Gaskets shall be used on a first-in, first-out basis.

F. Lined and/or coated pipe shall be suitably protected from exposure and heating of the sun at all times following procedures recommended by the coating/lining system manufacturer. Exposure will not be allowed (except for short periods such as installation, assembly and repairs).

G. No metal tools or heavy objects shall be permitted to come in contact unnecessarily with the finished coating. Workers will be permitted to walk upon the coated pipe only when necessary, in which case they shall wear footwear with rubber or composition soles and heels that are sufficiently free of dirt and mud that coating remains undamaged.

H. It shall be the responsibility of the Contractor to prevent damage to the linings and coatings that might be caused by handling and/or onsite storage of the finished pipe at low temperatures (due to embrittlement), high temperatures or direct sunlight.

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1.8 WARRANTIES

A. Provide warranties as required in Section GC-65.

PART 2 PRODUCTS

2.1 MATERIALS

A. Ductile iron pipe shall conform to AWWA C151. Pipe shall be supplied in standard lengths as much as possible.

B. Thickness design shall be per AWWA C150, except provide minimum Class 350 for piping 12-in and smaller, provide minimum Class 350 for piping from 14 to 20 inches and provide minimum Class 250 for piping larger than 24 inches. The pipe supplier shall perform thickness analysis as referenced in Paragraph 2.02. All ductile iron pipe supplied shall meet the minimum wall thickness and pressure class indicated on the drawings.

C. Ductile iron pipe for gravity sewer shall conform to ASTM A746 standards.

2.2 DUCTILE IRON PIPE DESIGN

A. Ductile iron pipe shall have a minimum tensile strength of 60,000 psi with minimum yield strength of 42,000 psi (per AWWA M-41). Design shall be done for external and internal pressures separately using the larger of the two for the net design thickness. Additional allowances shall be made for service allowance and casting tolerance per AWWA C150. The pipe classes determined for various sizes and conditions shall provide the total calculated thickness at a minimum or conform to minimum pipe class specified in Paragraph 2.01A2 above, or as shown on the Drawings, whichever is greater.

B. Design for the net thickness for external loading shall be taken as the greater of the following conditions:

1. 2-1/2-feet of cover with AASHTO H-20 wheel loads, with an impact factor of 1.5.

2. Depth from existing ground level of future proposed grade (whichever is greater) to top of pipe as shown on the Drawings, with truck load.

3. Soil Density: 125 lbs/cu ft

4. Laying Conditions; AWWA C150, Type 2.

C. Design for the net thickness shall be based upon the following internal pressure conditions:

1. Design pressure: 150 psi

2. Surge allowance: 100 psi

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3. Safety factor: 2

4. Total internal pressure design: 2 (150 + 100) = 500 psi 5.

E': 300 psi

D. Copies of design calculations showing that the pipe meets all the requirements specified herein shall be furnished to the Engineer for approval during shop drawing review in accordance with Section 01300. A yield strength of 42,000 psi shall be used during design calculations.

2.3 END TREATMENTS/JOINTS

A. Ductile iron pipe/fitting joints shall be push-on rubber gasket type or rubber-gasket mechanical joint per AWWA C111 in unrestrained areas, except where flanged joints are required as shown on the drawings. In restrained areas, both pipe and fitting joints shall be push on rubber gasket, locking ring type restrained joints per the manufacturer' standard described in Paragraph C, except where flange joints are shown on the Drawings. All gasket materials shall comply with Table 5-1 of AWWA M-41. [Rubber- gasket joints shall conform to AWWA C111. Gasket shall be of styrene butadiene rubber (SBR).

B. Unless otherwise noted, all ductile iron pipe/fitting joints shall be push-on rubber gasket type per AWWA C111 in unrestrained areas.

C. Restraint for push on joint pipe shall be positive locking "Locked-type" joints manufactured by the pipe and fitting manufacturer that utilize restraint independent of the joint gasket. All restrained joints shall be suitable for the specified 150 psig test pressure. Joints shall be fabricated of heavy section ductile iron casting. Bolts and nuts shall be [low carbon steel conforming to ASTM A193, Grade B7. Restraint for mechanical joint pipe shall use retainer glands for restraining joint. Restrained push on joints shall be by one of the following or an approved equal:

1. "TR Flex" by US Pipe and Foundry Company

2. "Lok-Ring, "Flex Ring (positive locking style)" by the American Cast Iron Pipe Company

3. "Snap Lok" by Griffin Pipe Products Company.

4. "Superlok" by Clow Water Systems Company

5. The minimum number of restrained joints required for resisting forces at fittings and changes in direction of the pipe shall be determined from the length of restrained pipe on each side of the fittings and changes in direction necessary to develop adequate resisting friction with the soil. The required lengths of restrained joints shall be as shown on the Drawings.

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6. Restrained pipe joints that achieve restraint by incorporating cut out sections in the wall of the pipe shall have a minimum wall thickness at the point of the cut out that corresponds with the minimum specified wall thickness for the rest of the pipe.

7. For up through 48-inch diameter ductile iron pipe only, the following may be used as an alternative restraint system: a. The optional mechanical joint restraint shall be incorporated in the design of a

follower gland. The gland shall be manufactured of ductile iron conforming to ASTM A536. Dimensions of the gland shall be such that it can be used with the standard mechanical joint bell and tee-headed bolts, as specified with the pipe.

b. The restraint mechanism shall consist of numerous individually activated gripping surfaces to maximize restraint capability. The gripping surfaces shall be wedges designed to spread the bearing surfaces on the pipe. Actuation of the gripping wedges shall be by torque limiting twist-off nuts [sized same as T bolts for mechanical joints]. When the nut is sheared off, standard hex nut shall remain.

c. The restraint device for ductile iron pipe shall have a working pressure of at least 250 psi and a safety factor of 2:1.

d. Pipe manufacturer proprietary mechanical joint restraint systems that utilize a wedge style gripping systems or a gland/ring positive restraint system will be considered acceptable on a case by case basis as determined by the Engineer.

e. The restraint device shall be EBAA Iron Megalug Series 1100, or approved equal.

D. Threaded ductile iron flanges for ductile iron pipe shall be fabricated per AWWA C115

and sealed during installation with a special high pressure, full face gasket per AWWA C111. At the pipe manufacturer's option, the use of 250 lb pattern flanges, which are faced and drilled in accordance with ANSI B16.1 may be substituted in order to match valves or other equipment and/or to meet the required working pressure requirements. All flanges shall be rated for the same pressure as the adjacent pipe in all cases. Compatibility of the flanges with the 250 lb class and higher special class AWWA valves will the responsibility of the Contractor.

1. Flanges shall be pre-drilled and then faced after being screwed onto the pipe, with flanges true to 90 degrees of the pipe axis and shall be flush with the end of the pipe.

2. Gaskets shall be full face rubber, 1/8-inch thick SBR material. Such as American Torseal Gasket, or approved equal. [Special material ring gaskets such as those by Garlock or equal may be required for pressures exceeding 250 for ANSI rated and custom flanges.]

3. Flanged joints shall be supplied with bolts and nuts on one end, bolt studs with a nut at each end, or studs with nuts on one end where the flange is tapped. The number and size of bolts shall comply with the same standard as the flange. Bolts and nuts shall, except as otherwise specified or noted in the Specifications or on the Drawings, comply with ASTM A193, grade B7.

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4. Blind flanges shall mate with regular flanges.

5. Filler flanges and beveled flange fillers shall be furnished faced and drilled complete with extra length bolts.

E. Couplings and Adapters

1. Sleeve type couplings shall be Dresser Style 38, 138 or equal by Ford Meter Box Co., Smith Blair or Romac industries. a. Buried sleeve-type couplings shall have a protective wrapping of "Denso"

material by DENSO Inc. of Texas or equal. Where "Denso" material is used, the joint shall be packed up with "Densyl mastic" to give an even contour for wrapping with "Densopol" tape. A 1.5 mm thick coating of "Denso" paste shall be applied following by 100 mm or wider "Densopol" tape wound spirally round the joint with at least 50 percent overlap.

b. Split Sleeve type flexible couplings shall be Victaulic Depend-O-Lok Style ExE unrestrained or FxF self-restrained or equal.

c. Grooved flexible joints for ductile iron pipe sizes 36-inhc and smaller must be in accordance with AWWA C606 and shall be Victaulic Style 31 or equal.

d. Shouldered flexible joints for ductile iron pipe sizes larger than 36-inch shall be Victaulic Style 44 or equal.

2.4 FITTINGS

A. Pipe fittings shall be ductile iron with pressure rating of 350 psi for 24 inches and smaller piping and 250 psi for 30 inches and larger piping. Fittings shall meet the requirements of AWWA C110 or AWWA C153 as applicable. Fittings shall have the same pressure rating, as a minimum, of the connecting pipe.

B. Closures shall be made with mechanical joint ductile iron solid sleeves unless alternate approved coupling systems as described in paragraph 2.03E are used and shall be located in straight runs of pipe at minimum cover outside the limits of restrained joint sections. Location of closures shall be subject to approval of the Engineer.

2.5 INTERIOR LINING

A. Ductile iron pipe and fittings shall have the same type of lining as specified herein.

B. At the option of the supplier, fittings may be lined in accordance with AWWA C550. Lining shall be NSF 61 certified.

C. Ductile iron pipe and fittings shall be lined with a ceramic-filled amine-cured epoxy, Protecto 401 by Induron. The lining thickness shall be 40 mils minimum. Application shall be performed by an applicator approved by the coating manufacturer, in accordance with manufacturer's instructions and under controlled conditions at the applicator's shop or the pipe manufacturer's plant. Applicator shall submit a certified affidavit of compliance with manufacturer's instructions and requirements specified herein.

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2.6 EXTERIOR COATING

A. Buried pipe shall be installed with a bituminous coating in accordance with AWWA C151 and C110 respectively.

B. Buried pipe shall be installed with polyethylene encasement. Polyethylene encasement shall have a minimum thickness of 8 mils and meet or exceed the minimum standards established by AWWA C105, current edition. Acceptable manufacturers include North Town Company; AA Thread and Seal Tape, Inc.; Sigma Corp. or approved equal.

1. Polyethylene encasement shall meet minimum size requirements per TABLE 3 of section 2.15 of DIPRA's Installation Guide for Ductile Iron Pipe.

2. Test results from an independent testing agency certifying that the polyethylene encasement meets all criteria established by AWWA C105, current edition, shall be submitted to the Engineer prior to approval of the polyethylene encasement for use. In general, samples shall be submitted and include test results in accordance with the AWWA standard associated with tensile strength, elongation, dielectric strength, impact resistance, and propagation tear resistance.

3. A 2-inch wide plastic adhesive tape, such as Calpico Vinyl, Polyken, U.P.C. Tape, or approved equal, shall be used for sealing seams, cuts, or tears in polyethylene encasement. Duct tape shall not be allowed.

PART 3 EXECUTION

3.1 GENERAL

A. Care shall be taken in loading, transporting and unloading to prevent injury to the pipe, lining or coatings. Pipe and fittings shall not be dropped or skidded against each other. Slings, hooks or pipe tongs shall be used for pipe handling. All pipe and fittings shall be examined before laying and no piece shall be installed which is found to be defective. Any damage to the pipe, lining or coatings shall be repaired per manufacturer's recommendations. Handling and laying of pipe and fittings shall be in accordance with manufacturer's instruction and as specified herein.

B. If any defective pipe is discovered after it has been laid, it shall be removed and replaced with a sound pipe in a satisfactory manner. All pipe and fittings shall be thoroughly cleaned before laying, shall be kept clean until they are used in the work and when installed or laid, shall conform to the lines and grades required.

C. Materials, if stored, shall be kept safe from damage. The interior of all pipe, fittings and other appurtenances shall be kept free from dirt, excessive corrosion or foreign matter at all times.

D. Pipe shall not be stacked higher than the limits recommended by its manufacturer. The bottom tier shall be kept off the ground on timbers, rails, or concrete. Stacking shall conform to manufacturer's recommendations and/or AWWA C600.

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E. Gaskets for mechanical and push-on joints to be stored shall be placed in a cool location out of direct sunlight. Gaskets shall not come in contact with petroleum products. Gaskets shall be used on a first-in, first-out basis.

3.2 INSTALLING DUCTILE IRON PIPE AND FITTINGS

A. Ductile iron pipe and fittings shall be installed in accordance with requirements of [the laying schedule] AWWA C600, except as otherwise specified herein. A firm, even bearing throughout the length of the pipe shall be provided by digging bell holes at each joint and by tamping backfill materials at the side of the pipe to the springline per details shown on the Drawings. Blocking will not be permitted. If any defective pipe or fitting is discovered after it has been laid, it shall be removed and replaced with a sound pipe or fitting in a satisfactory manner by the Contractor, at his/her own expense.

1. All pipe and fittings shall be kept clean until they are used in the work and shall be sound and thoroughly cleaned before laying. When laid, the pipe and fittings shall perform to the lines and grades required. When laying is not in progress, including lunch breaks, open ends of the pipe shall be closed by a watertight plug or other approved means. Sufficient backfill shall be placed to prevent flotation. The deflection at joints shall not exceed that recommended by the manufacturer.

2. All ductile iron pipe laid underground shall have a minimum of 3 feet of cover unless otherwise shown on the Drawings or as specified herein. Pipe shall be laid such that the invert elevations shown on the Drawings are not exceeded.

3. Fittings, in addition to those shown on the Drawings shall be provided, where required, in crossing utilities which may be encountered upon opening the trench. Solid sleeve closures shall be installed at locations approved by the Engineer.

4. The pipe interior shall be maintained dry and broom clean throughout the construction period.

5. When field cutting, the pipe is required, the cutting shall be done by machine, leaving a smooth cut at right angles to the axis of the pipe. The end of the cut pipe shall be beveled to conform to the manufacture's recommendations for the spigot end. Any coating removed from the cut end shall be repaired according to manufacturer's recommendation and/or Section [2.06] (whichever method is more stringent in the opinion of the Engineer). [Cement] lining shall be undamaged. Cutting of restrained joint pipe will not be allowed, unless approved at specific joints in conjunction with the use of restrainer glands by EBAA Iron or field adaptable restrained joints. Where field cuts are permitted, the pipe to be cut shall be supplied by the factory as "gauged full length". Should full length gauged pipe be unavailable, the pipe to be cut shall be field gauged at the location of the new spigot using a measuring tape, or other means approved by the manufacturer, to verify that the diameter is within the tolerances permitted in Table 1 of AWWA C151.

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B. Jointing Ductile-Iron Pipe

1. Push-on joints shall be made in strict accordance with manufacturer's instructions, AWWA C600 and Appendix B of AWWA C111. If there is conflict, the manufacturer's instructions shall take precedence. Pipe shall be laid with bell ends looking ahead. A rubber gasket shall be inserted in the groove of the bell end of the pipe. The joint surfaces shall be cleaned and lubricated and the plain end of the pipe shall be aligned with the bell of the pipe to which it is to be joined and pushed home. After joining the pipe, a metal feeler shall be used to make certain that the rubber gasket is properly seated.

2. Mechanical joints shall be assembled in strict accordance with the manufacturer's instructions, AWWA C600 and Appendix A of AWWA C111. If there is conflict, the manufacturer's instructions shall take precedence. Pipe shall be laid with bell ends looking ahead. To assemble the joints in the field, thoroughly clean and lubricate the joint surfaces and rubber gasket. Bolts shall be tightened to the specified torques. Under no condition shall extension wrenches or pipe over handle of ordinary ratchet wrench be used to secure greater leverage. After installation, apply a bitumastic coating to bolts and nuts and install polyethylene encasement as specified.

3. Bolts in mechanical or restrained joints shall be tightened alternately and evenly. Restraint for mechanical joint pipe shall use retainer glands for restraining joint. All restrained mechanical joints shall be suitable for the specified test pressure.

4. Restrained joints shall be installed according to pipe manufacturer's instructions.

5. Flanged joints shall be assembled in strict accordance with the manufacturer's instructions and Appendix C of AWWA C111. If there is conflict, the manufacturer's instructions shall take precedence. Extreme care shall be taken to ensure that there is no restraint on opposite ends of pipe or fitting, which would prevent uniform gasket compression, cause unnecessary stress, bending or torsional strains, or distortion of flanges or flanged fittings. Adjoining push on joints shall not be assembled until flanged joints have been tightened. Flange bolts shall be tightened uniformly to compress the gasket uniformly and obtain a seal. Flange bolts shall be left with approximately 1/2-inch projection beyond the face of the nut after tightening. After installation apply a bitumastic coating to the bolts and nuts as specified.

6. Sleeve couplings shall only be installed for closure or as shown on the Drawings. Couplings shall not be assembled until adjoining joints have been assembled. After installation. Apply a heavy bitumastic coating to the bolts and nuts and install protective wrap recommended by the manufacturer or as required herein. Care shall be exercised to ensure that the insulating properties of insulating and dielectric couplings are maintained.

C. All blowoffs, outlets, valves, fittings and other appurtenances required shall be set and jointed as indicated on the Drawings in accordance with manufacturer's instructions.

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D. Install polyethylene encasement around ductile iron pipe to limits shown on the Drawings and in accordance with pipe manufacturer's recommendations.

1. Polyethylene encasement shall be installed per ANSI/ AWWA C105/A21.5,

Method 'A' in accordance with section 2.15 of DIPRA's Installation Guide for Ductile Iron Pipe.

2. A fabric type or padded sling shall be used when handling polyethylene encased

pipe to prevent damage to the polyethylene encasement.

3. All seams in the polyethylene encasement shall be sealed completely with approved 2-inch wide plastic adhesive tape.

4. Extreme care shall be taken to ensure that all rips or tears in the polyethylene encasement are properly repaired with additional tape and film as described in ANSI/AWWA C105/A21.5

5. Extreme care shall be taken when backfilling to avoid damaging the polyethylene encasement

6. Factory applied copper conductivity straps may be used in lieu of field applied bonding wire.

3.3 CONNECTIONS TO STRUCTURES

A. Wherever a pipe 3 inches in diameter, or larger, passes from concrete to earth horizontally, two flexible joints spaced from 2 to 4 feet apart depending on pipe size shall be installed, within 2 feet of the exterior face of the wall, whether or not shown on the Drawings.

B. Unless otherwise specified, all pipes passing through a wall will utilize a wall sleeve designed to pass the thrust through the wall via restrained piping.

C. Piping underneath structures shall be concrete encased.

3.4 FILLING AND TESTING

A. After installation, the pipe shall be tested for compliance as specified herein. Furnish all necessary equipment and labor for the hydrostatic pressure test on the pipelines.

B. Submit detailed test procedures and method for Engineer's review. In general, testing shall be conducted in accordance with AWWA C600. The method and procedures for performing the hydrostatic pressure test shall be approved by the Engineer. Submit the plan for testing to the Engineer at least 10 days before starting a test.

C. Pressure pipelines shall be subjected to a hydrostatic pressure of 1.25 times the working pressure at the highest point along the test segment. This test pressure shall be maintained for a minimum of 2 hours. The hydrostatic testing allowances shall not exceed those indicated in AWWA C600. Provide suitable restrained bulkheads as required to complete the hydrostatic testing specified.

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D. Contractor shall make any taps and furnish all necessary caps, plugs etc., as may be required in conjunction with performing the testing.

E. Gravity pipelines shall be subjected to hydrostatic pressure test as specified in AWWA

C600.

F. All valves and valve boxes shall be properly located and installed and operable prior to testing. Bulkheads shall be provided with a sufficient number of outlets for filling and draining the line and for venting air.

G. Hydrostatic pressure tests shall conform to Section 5.2 of AWWA C600. Furnish gauges, meters, pressure pumps and other equipment needed to fill the line slowly and perform the required hydrostatic pressure tests.

H. The Owner shall supply, at no cost to the Contractor, a maximum quantity of water equal to 110 percent of the volume of the pipelines for testing. Additional water required by the Contractor will be provided at standard billing rates for the volume required. The line shall be slowly filled with water and the specified test pressure shall be maintained in the pipe for the entire test period by means of a pump furnished by the Contractor. Provide accurate means for measuring the quantity of makeup water required to maintain this pressure.

I. Duration of pressure test shall not be less than 2 hours. All leaks evident at the surface shall be repaired and leakage eliminated regardless of the total leakage as shown by test. Lines which fail to meet tests shall be repaired and retested as necessary until test requirements are complied with. Defective materials, pipes, valves and accessories shall be removed and replaced.

3.5 CLEANING

A. At the conclusion of the work, thoroughly clean all of the pipe by flushing with water or other means to remove all dirt, stones, pieces of wood, or other material which may have entered during the construction period. All debris shall be removed from the pipeline. The lowest segment outlet shall be flushed last to assure debris removal.

B. After the pipe has been cleaned and if the groundwater level is above the pipe or water in the pipe trench is above the pipe following a heavy rain, the Engineer will examine the pipe for leaks. If defective pipes, fittings or joints are discovered at this time, they shall be repaired or replaced by the Contractor.

END OF SECTION

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Fiberglass Gravity Sewer Pipe 02627-1


SECTION 02627 FIBERGLASS

GRAVITY SEWER PIPE

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment, and incidentals required, and install fiberglass-reinforced polymer mortar pipe, manhole structures, and appurtenances as shown on the Drawings and as specified herein.

1.2 RELATED WORK

A. Pipeline Cleaning and Testing are included in Section 01445.

B. Trenching, Backfilling and Compaction are included in Section 02221.

C. Precast concrete structures are included in Section 03410.

1.3 SUBMITTALS

A. Submit, in accordance with Section 01300, detailed shop drawings and schedules of all pipe and

fittings required. Submittals shall include the following:

1. Product data submittals to include the following, as a minimum:

a. Details of the proposed pipe installation.

b. Properties and strengths of the pipes.

c. Details of joints.

d. Pipe design load calculations as prepared and sealed by a Professional Engineer registered in the State of North Carolina.

e. Instruction on storage, handling, transporting, and installation.

f. Standard catalog sheets.

g. Material certifications.

h. Details of pipe/manhole connections.

2. Shop drawings shall include a pipe class laying schedule which specifies pipe class, class

coding, joints, station limits, and transition stations, and a list of abbreviated terms with their full meaning. Provide details of fittings to be furnished. The above shall be submitted to the Engineer for approval before fabrication and shipment of these items. The locations of all pipes shall conform to the locations indicated on the Drawings.

3. Furnish in duplicate to the Engineer, prior to each shipment of pipe, sworn certificates

furnished in duplicate to the Engineer prior to each shipment of pipe that all tests and inspections specified herein under which the pipe is manufactured have been satisfied.

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4. The pipe manufacturer shall inspect all pipe joints for out-of-roundness and pipe ends for squareness. The manufacturer shall furnish to the Engineer a notarized affidavit stating all pipe meets the requirements of AWWA, ASTM, ANSI, etc., this Section, and the joint design with respect to square ends and out-of-round joint surfaces.


A. American Water Works Association (AWWA)

1. AWWA M45 – Fiberglass Pipe Design

B. American Society for Testing and Materials (ASTM)

1. ASTM D2321 - Standard Practice for Underground Installation of Thermoplastic Pipe for

Sewers and Other Gravity-Flow Applications

2. ASTM D2412 - Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading.

3. ASTM D 3262 – Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced

Thermosetting-Resin) Sewer Pipe.

4. ASTM D3681 - Standard Test Method for Chemical Resistance of "Fiberglass" (Glass- Fiber-Reinforced Thermosetting-Resin) Pipe in a Deflected Condition.

5. ASTM D3839 - Standard Guide for Underground Installation of “Fiberglass” (Glass-Fiber-

Reinforced Thermosetting-Resin) Pipe

6. ASTM D4161 - Standard Specification for "Fiberglass" (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe Joints Using Flexible Elastomeric Seals.

7. ASTM F477 - Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic

Pipe.



A. All pipe and fittings shall be from a single manufacturer located within the continental United States

of America. The supplier shall be responsible for the provisions of all test requirements specified in ASTM D3262, as applicable. In addition, all piping to be installed under this Contract may be inspected at the plant for compliance with this Section by an independent testing laboratory acceptable to the Owner. The Contractor shall require the manufacturer's cooperation in these inspections. The cost of plant inspection of all pipe approved for this Contract will be borne by the Contractor.

B. Inspections of the pipe may also be made by the Engineer or other representatives of the Owner

after delivery. The pipe shall be subject to rejection at any time on account of failure to meet any of the requirements specified herein, even though sample pipes may have been accepted as satisfactory at the place of manufacture. Pipe rejected after delivery shall be marked for identification and shall be removed from the job at once.

C. Pipe and fittings shall be manufactured by HOBAS or U.S. Composite Pipe South – Flowtite.

Bid Set April 2017




A. Care shall be taken in shipping, handling, and laying to avoid damaging the pipe and fittings. Follow the manufacturer's recommendations during unloading, handling, storing, stringing, and installing the pipe and fittings. Any pipe or fitting damaged in shipment shall be replaced as directed by the Engineer.

B. Any pipe or fitting showing a crack or which has received a blow that may have caused an

incipient fracture, even though no such fracture can be seen, shall be marked as rejected and removed at once from the work.

PART 2 PRODUCTS

2.1 FIBERGLASS PIPE

A. Pipe:

1. The pipe shall be manufactured in accordance with ASTM D3262 with a minimum pipe

stiffness of F/y = 46 psi or F/y = 72 psi as shown on the Drawings. The pipe shall meet the following cell limits: Type 1, Liner 2, Grade 3, or Type 1, Liner 1, Grade 1 as described by Section 4.2 and Table 1 of ASTM D3262. The stiffness is to be measured in accordance with ASTM D2412. The corrosion liner shall not be considered as contributing to the structural strength of the pipe. The pipe shall be as manufactured by Hobas Pipe USA or equal.

2. The pipe shall be manufactured by the centrifugal casting or filament wound process resulting

in a dense, nonporous, corrosion-resistant, consistent, composite structure to meet the operating conditions as shown on the Drawings. The pipe shall also meet the strain corrosion-resistant requirements of ASTM D3681 for a maximum long-term deflection of 5 percent.

The pipe shall meet or exceed the 50-year strain requirements of ASTM D3262 when tested in accordance with ASTM D3681. The corrosion liner/interior surface shall have a minimum thickness of 0.06-inch resin. The liner/interior surface may be non-reinforced resin or resin reinforced with chopped fiberglass as determined by the manufacturer.

3. Stiffening ribs or rings shall not be used.

B. The Contractor shall submit pipe thickness calculations to the Engineer for review. The pipe shall be

designed in accordance with the applicable provisions of AWWA M45 and shall meet the following design conditions:

1. AASHTO H-20 Live Load.

2. A soil modulus of elasticity of 2,000 psi and a soil weight 120 pounds per cubic foot.

3. Safety factor of 2.5.

4. Groundwater levels shall be estimated to be at the ground surface.

5. Service temperature range shall be 40 to 90 degrees F.

6. Maximum long term deflection shall be 5 percent.

Bid Set April 2017



7. The thickness to be used for the CCFR pipe shall be the largest thickness as determined by calculations for deflection, bending, buckling and minimum stiffness.

8. The pipe shall have a minimum nominal pipe stiffness of 72 psi. Thicknesses shall be

increased as necessary based on the pipe design and thickness calculations.

C. Pipe shall be furnished in standard laying lengths not exceeding 20 feet. When required by radius curves, pit size, or sewer irregularity, pipe shall be supplied in nominal lengths of 10 feet or other even divisions of 20 feet.

D. All fittings and accessories shall be furnished by the pipe supplier and shall have joint

configurations compatible with the pipe.

E. Each length of pipe shall be marked with the nominal size, the pipe stiffness designation, name of manufacturer, date of manufacture and/or acceptance.

F. Complete records of inspections, examinations and tests performed by the manufacturer shall be

kept and submitted to the Owner and Engineer.

C. Couplings:

1. Unless otherwise specified, the pipe shall be field connected with filament-wound fiberglass exterior sleeve couplings or bell-spigot couplings that utilize elastomeric sealing rings, meeting requirements of ASTM F477, as the sole means to maintain joint watertightness. The joints must meet the performance requirements of ASTM D4161.

C. Manhole Connections

1. Pipe connections and stubs for all manhole structures and manhole connections shall not be

less than 4 feet in length. Caps shall be furnished where required. Submit a shop drawing detailing the method of connecting the proposed pipe to the manhole.

2.2 TRACER WIRE

A. Provide minimum 12-gauge solid copper tracer wire encased in 30 mils of HDPE insulation for all

fiberglass pipe. Provide blue wire for water pipe and green wire for sewer pipe.

B. Provide tracer wire connection point at each isolation valve location for water or forcemains and at each manhole and cleanout for sanitary sewers. See drawings for additional details.

PART 3 EXECUTION

3.1 LAYING FIBERGLASS PIPE AND FITTINGS

A. If any defective pipe is discovered after it has been installed, it shall be removed and replaced or

repaired as directed by the Engineer with a sound pipe in a satisfactory manner at no additional cost to the Owner. All pipe and fittings shall be thoroughly cleaned before installation, shall be kept clean until they are used in the work, and when installed, shall conform to the lines and grades required.

B. Fiberglass sewer pipe shall be laid in accordance with the instructions of the manufacturer, as

specified herein, and as specified in Section 02221. Embedment of pipe shall conform to the details shown on the Drawings and the requirements in ASTM D2321. Proper selection and placement of bedding and backfill materials are necessary to minimize deflection of the pipe diameter. No blocking under the pipe will be permitted.

Bid Set April 2017



C. Use care in handling and installing pipe and fittings in accordance with manufacturer's recommendations. Handling of the pipe with chains or wire cables shall not be permitted. Storage of pipe on the job site shall be done in accordance with the pipe manufacturer's recommendation and with approval of the Engineer. Under no circumstances shall pipe or fittings be dropped either into the trench or during unloading. The interior of the pipe shall be kept clean of oil, dirt, and foreign matter, and the machined ends and couplings shall be wiped clean immediately prior to jointing.

D. Use a pipe cutter where necessary to cut and machine all pipe in the field. A "full insertion mark"

shall be provided on each field-cut pipe end. Field-cut pipe shall be beveled with a beveling tool in accordance with the manufacturer's recommendations. Bevels shall be in accordance with the manufacturer's requirements.

E. Rubber gaskets shall be marked with manufacturer's identification sizes and proper insertion

direction.

F. Before being laid, all pipe and specials shall be thoroughly examined for defects, and no piece shall be installed which is known to be defective. If any defective piece should be discovered after having been installed, it shall be removed and replaced with a sound one in a satisfactory manner at no additional cost to the Owner.

G. For open-trench construction, the laying of the pipe in finished trenches shall begin at the lowest

point, with the coupling/bell ends pointing opposite to the direction of flow. The interior of the pipe and the jointing seal shall be free from sand, dirt, and trash before installing in the line. Extreme care must be taken to keep the couplings of the pipe free from dirt and rocks so joints may be properly assembled without overstressing the coupling. The jointing of the pipe shall be done in strict accordance with the pipe manufacturer’s instructions and shall be done entirely in the trench.

H. The pipe shall be thoroughly cleaned before it is laid and shall be kept clean until it is accepted in the

completed work. Special care shall be exercised to avoid leaving bits of wood, dirt, and other foreign particles in the pipe. If any such particles are discovered before the final acceptance of the work, they shall be removed and the pipe cleaned at no additional cost to the Owner.

I. Each time the work is halted for more than 1 hour; the ends of the pipe shall be sealed to

prevent foreign material from entering the pipe.

J. Jointing

1. Clean ends of pipe and coupling components.

2. Check pipe ends and couplings for damage. Correct any damage found.

3. Coupling grooves must be completely free of dirt.

4. Apply joint lubricant to pipe ends and rubber seals of coupling. Use only lubricant approved by the pipe manufacturer.

5. A sleeve hole shall be made in the bedding material prior to joint assembly. When joint has

been made, the sleeve hole shall be filled with bedding material.

6. Use suitable auxiliary equipment, such as a wire rope puller, to pull pipe joints together. The jointing force should be applied to the pipe wall and not to the coupling.

Bid Set April 2017



7. Do not apply excess force in jointing the pipe. If excessive force is required, remove coupling, determine source of problem, and correct it before reassembling the joint.

8. In the process of jointing the pipe, joint the pipe in a straight, non-deflected alignment. Angular

deflection of the joint shall be accomplished after the joint is homed to the mark. Do not allow the deflection angle to exceed the maximum deflection permitted by the manufacturer.

K. Install tracer wire at the 12 o’clock position on the pipe exterior. Secure the tracer wire to the pipe

with adhesive tape (duct tape or similar) at minimum every 10 feet on center. See Drawings for additional details. Install tracer wire connection and termination points as shown on the Drawings. Following installation of tracer wire, the Contractor shall verify the continuity of the wire, repair any damaged sections and demonstrate the tracer wire system is providing an accurate location of the pipe.

3.2 ALLOWABLE DEFLECTION TEST

A. Pipe deflection measured not less than 30 days after the backfill has been completed as specified

shall not exceed 3.33 percent. Deflection shall be computed by multiplying the amount of deflection (nominal diameter less minimum diameter when measured) by 100 and dividing by the nominal diameter of the pipe.

B. Deflection shall be measured with a rigid mandrel (Go/No Go) device cylindrical in shape and

constructed with a minimum of nine evenly spaced arms or prongs. Drawings of the mandrel with complete dimensions shall be submitted to the Engineer for each diameter of pipe to be tested. The mandrel shall be hand pulled through all sewer lines.

C. Any section of sewer not passing the mandrel shall be uncovered at no additional cost to the

Owner and the bedding and backfill replaced to prevent excessive deflection. Repaired pipe shall

be retested at no additional cost to the Owner. Retested pipe shall not deflect more than 3 percent.

END OF SECTION

Bid Set April 2017

Plastic Lining for Precast Concrete 02765-1


SECTION 02765

PLASTIC LINING FOR PRECAST CONCRETE

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and apply premolded

self-anchoring plastic sheet linings to the following interior surfaces of precast and cast-in-place reinforced concrete structures.

1. Precast concrete manholes.

2. Cast-in-place reinforced concrete junction structures.

1.2 RELATED WORK

A. Precast Concrete Manholes are included in Section 02605.

B. Plastic Lining for Cast-in-place Concrete is included in Section 02766.

1.3 SUBMITTALS

A. Submit, in accordance with Section 01300, standard requirements and data covering the

materials to be furnished and detailed drawings covering the installation thereof, including but not limited to the attachment of the linings to the forms and the arrangement and sealing or welding of the butt and joints.

B. Furnish certification by the manhole and pipe manufacturers that the lining is of the

materials specified. No lined manhole or reinforced concrete structure sections will be accepted for use in the Work on this project until certificates have been submitted and approved.


A. The manufacturer of the sheet lining shall furnish an affidavit attesting to the successful and

completely satisfactory use of the materials as a lining for the service intended, before shipment thereof.

B. The accepted plastic sheet manufacturer's standard printed specifications covering the

installation of the lining in concrete structures shall be considered as being incorporated herein and all work for and in connection with said plastic lining installation shall be strictly in accordance therewith. Such manufacturer's specifications shall include and cover application of sheets to concrete forms, including preparation of forms, joint welding and removal of forms; miscellaneous requirements covering transportation, handling, storing and inspection; and necessary precautions with respect to ventilation and protection of workmen.

Bid Set April 2017



C. All work for, and in connection with, the installation of plastic sheet lining, and the preparation of surfaces and the sealing and welding of joints shall be performed by the manufacturer of the lining, or by a firm or individual(s) who has been trained and certified by said manufacturer.

D. Training certification shall be submitted by Contractor, from manufacturer, in writing. Only

trained and certified workers shall perform work associated with plastic linings. PART 2 PRODUCTS

2.01 MATERIALS

A. All liner plates furnished shall be: composed of chemically inert synthetic resin, pigments and

plasticizers suitably compounded and processed; formed under pressure into permanently flexible sheets; white in color and shall conform to the following:

1. Premolded Plastic Sheet Linings shall be Amer-Plate "T-Lock", not less than 0.065-

inch thick, as manufactured by Ameron, Corrosion Control Division, Brea, CA or equal.

2. Welding Strip shall be Amer-Plate "T-Lock" welding strip or equal.

3. All PVC liner materials shall be ultraviolet stabilized.

B. The PVC liner shall meet the following strength test requirements:

1. The test pull specified in the APWA Specifications shall be performed in the presence

of the purchaser or the purchaser's representative on a minimum of one lined pipe section for each 400 feet of pipe or 40 feet of manhole section produced for the project. The test shall be performed on liner in pipe selected by the purchaser or the purchaser's representative. The pull test of the liner shall be performed on a one inch to three-inch length of tee. Unless otherwise directed by the purchaser or the purchaser's representative, the location of the tests shall be within two feet of the end of the pipe, which is up during manufacturing, except that a minimum distance between the test location and the end of the sheet shall be six inches.

2. The pipe or manhole manufacturer shall submit his proposed method of making the

pull test to the purchaser for his approval prior to conducting the test.

3. In the event that one section of liner fails to withstand the required test; the manufacturer shall have the right to perform the test on the liner in two other sections selected by the purchaser from the same run from which the original liner was selected. If these two sections successfully pass the test, the remainder of the liner on that run will be accepted. If tests of either of these sections fail, the remainder of that run will not be accepted until a pull test of the liner in each of the pipe sections has satisfactorily passed the test. Locations of the additional pull tests shall be determined by the City inspector.

Bid Set April 2017



4. The liner in the test pipe which passes the pull test shall be repaired by fusion welding and shipped to the project site.

5. The Engineer may require additional pull tests if visual inspection reveals bumps or

imperfections that may indicate improper embedment of the liner PART 3 EXECUTION

3.1 INSTALLATION

A. Precast Concrete Sections

1. The vertical portion of the interior of all precast concrete manholes and reinforced

concrete pipes shall be sealed and protected with plastic lining where indicated on the Drawings. All outlets and connections within the designated limits of the plastic pipe lining shall be completely sealed and protected with the plastic pipe lining. Joints shall be kept at a minimum. Except where outlets are required, the plastic lining for each length of pipe shall consist of a single sheet of material. Where joints occur between individual sheets or sections of plastic liner, they shall be continuously heat-welded, either by lapping adjacent sheets or with the use of auxiliary welding strips cut from the same kind and thickness of material as the liner plates (with the exception of the T-lock ribs). At outlets, the lining shall be turned back into the joint or otherwise suitably terminated so that the edges are adequately protected and anchored.

2. The lining for each pipe or manhole section shall be furnished to the pipe

manufacturer as a single sheet.

3. The pipe liner shall extend to the end of the interior concrete surface at both bell and spigot end of the pipe. Unless otherwise authorized, a 4-in joint strip shall be molded integral with the plastic liner as furnished for installation in the pipe. This joint shall have no T-lock ribs on the back of the strip and is intended to lap over the lining of the adjacent pipe for field welding thereto. These joint extensions shall be made of the same material as used in the specified T-lock liner plates. The joint strip shall overlap the liner plate of the downstream pipe a minimum of 1-in. All adhesive, welding materials, separate strips of lining material for field joints (where authorized) shall be furnished by the lining material manufacturer.

C. All work in connection with the installation of the plastic lining in precast manhole sections

and concrete pipe shall be performed in strict conformity with the lining manufacturer's recommendation. Liner sheets shall be fastened in place securely in the forms for the manhole sections and concrete pipe before reinforcing steel or concrete is placed.

D. Care shall be taken in handling and transporting plastic lined manhole sections and pipe to

prevent damage to the liner. No interior hooks or other interior lifting device shall be used in handling the manhole sections and pipe; all handling requiring lifting or suspension shall be done by using exterior slings. No manhole sections or pipe with damaged lining will be accepted until and unless the damage has been repaired to the satisfaction of the Owner.

Bid Set April 2017



E. Repairs

1. All repairs to damaged portions of the linings shall be made and all holes in the linings sealed before final acceptance of the work, in conformity with the lining manufacturer's instructions and recommendations. The requirement for neat, high quality work is emphasized.

F. Testing

1. All surfaces covered with the lining shall be tested with an acceptable electrical

holiday or flaw detector after installation and any imperfections discovered thereby shall be repaired as specified above.

3.2 FIELD JOINTS IN PLASTIC LINING

A. The joint between plastic lined pipes or manhole sections shall be prepared in the

following manner before making the lining joints:

1. The inside joint shall be filled and carefully pointed with cement mortar for the full circumference of the pipe or manhole section. The mortar shall not, at any point, extend into the pipe or manhole section beyond a straight line connecting the surfaces of the adjacent pipe or manhole sections.

2. No manhole lining joint shall be made until after the trench has been backfilled. Pipe

and manhole joints must be dry before lining joints are made. All mortar and other foreign material shall be removed from lining surfaces adjacent to the pipe or manhole joint.

B. Field joints in the lining at pipe or manhole joints may be either of the following described

types:

1. The joint shall be made with a separate 4-in wide joint strip and two, 1-inch wide welding strips. The 4-inch strip shall be centered over the joint, secured to the lining with an adhesive compound and welded along each edge to adjacent liner sheets. The width of the space between the ends of pipe lining material shall not exceed 2 inches. The 4-inch joint strip shall overlap the lining in each pipe a minimum of 1 inch.

2. The joint shall be made with a lining flap extending about 3-in beyond the spigot end

of the precast concrete section. One welding strip is required. The joint flap shall overlap the lining in the adjacent precast concrete section a minimum of 1-in. An adhesive compound shall be used to hold the flap in place during welding. The flap shall be protected from damage during installation. Excessive tension and distortion in bending back the strip to expose the pipe or manhole joint during laying and joint mortaring shall be avoided.

3. All joints between pipe and wall fittings in precast concrete sections and between

wall fitting and lining of manhole walls, where lining is required, shall be made by one of the two ways described above.

Bid Set April 2017



4. All welding of joints shall be in strict conformity with the recommendations of the lining manufacturer.

3.3 TESTING AND REPAIRING

A. After the precast concrete is installed and backfilled, where is required, all surfaces covered

with plastic lining, including welds, shall be tested with an electric holiday detector. The voltage and specific methods of testing shall be as recommended by the manufacturer of the lining material. In addition, all welds shall be physically tested by non-destructive probing. All patches over holes, or repairs to the liner wherever damage has occurred, shall be installed in conformity with the instructions and recommendations of the liner manufacturer.

B. Each transverse welding strip which extends to a lower edge of the liner shall be tested. The

welding strip shall extend 2 inches below the liner to provide a tab. The force shall be applied normal to the face of the structure by means of a spring balance. Liner adjoining the welding strip shall be held against the concrete during application of the force. The 10-pound pull shall be maintained if a weld failure develops, until no further separation occurs. Defective welds shall be retested after repairs have been made. Tabs shall be trimmed away neatly after the welding strip has passed inspection. Inspection shall be made within 2 days after joint has been completed.

END OF SECTION

Bid Set April 2017




Bid Set April 2017

Plastic Lining for Cast-In-Place Concrete 02766 - 1


SECTION 02766

PLASTIC LINING FOR CAST-IN-PLACE CONCRETE

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and install polyvinyl chloride lining system (PVC liner) on cast-in-place concrete as specified herein. The PVC liner system shall consist of both PVC sheet liner cast integrally with concrete and PVC sheet liner installed in mastic over existing concrete. The PVC liner system shall fully adhere to the structure interior surfaces in accordance with the limits shown on the Contract Drawings.

B. All work, for and in connection with the installation of the lining and the field sealing and welding of joints, shall be performed in strict conformity with all applicable specifications, instructions and recommendations of the liner manufacturer.

1.2 RELATED WORK

A. Concrete formwork is included in Section 03100.

B. Cast-In-Place concrete is included in Section 03300.



1. ASTM D412 - Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension

2. ASTM D570 - Standard Test Method for Water Absorption of Plastics

3. ASTM D696 - Standard Test Method for Coefficient of Linear Thermal Expansion of Plastics Between −30 degrees C and 30 degrees C with a Vitreous Silica Dilatometer

4. ASTM D1044 - Standard Test Method for Resistance of Transparent Plastics to Surface Abrasion

5. ASTM D1894 - Standard Test Method for Static and Kinetic Coefficients of Friction of

Plastic Film and Sheeting

6. ASTM D2240 - Standard Test Method for Rubber Property—Durometer Hardness


Bid Set April 2017



1.4 SUBMITTALS

Submit, in accordance with Section PR-9, the following items. Liner fabrication shall not begin until shop drawings and submitted materials have been reviewed and accepted by the Engineer.

A. Shop drawings that include a materials list for the lining including material safety data sheets and laboratory test data.

B. A complete description of the lining system installation including, as a minimum, substrate preparation including equipment and setup (where appropriate), inspection and testing, PVC liner sheet sizes and layout, field sealing and welding of joints, and site-specific detailed drawings of all areas of special construction including, but not necessarily limited to, seams, corners, pipe penetrations, manhole connections, concrete benching, termination strips, and any other miscellaneous penetrations.

C. Welder certifications by the manufacturer for each applicator installing the lining system.

D. Affidavit from the liner manufacturer attesting to the successful use of its PVC lining material in similar service for a minimum period of 50 years in sewage conditions recognized as corrosive or otherwise detrimental to concrete.

E. Description of installer experience in accordance with the requirements herein.


A. All specified materials shall be installed in strict accordance with the manufacturer’s application or installation instructions.

B. The work shall be performed by a contractor or subcontractor who is trained by the manufacturer of the PVC liner system.

1. Personnel installing PVC sheet liner cast integrally in concrete shall have a minimum of 10,000 square feet of installation experience using the specified product.

2. Personnel installing PVC sheet liner installed in mastic over existing concrete shall have a minimum of 3,000 square feet of installation experience using the specified product.

C. Each applicator who will install the PVC liner system shall be trained by the liner manufacturer and pass a qualification welding test before performing any welding. Each applicator shall be in possession of a liner manufacturer issued identification card with a valid date indicating the individual applicator is approved to install the product. This identification card shall be presented at any time upon request to the project Owner, Engineer, manufacturer, or designated inspector. Requalification may be required at any time deemed necessary by the Engineer or Owner. All requalification test welds to certify an applicator shall be made in the presence of the Owner’s representative and liner manufacturer and shall consist of the following:

Bid Set April 2017



1. Two pieces of liner at least 15-in long and 4-in wide, shall be lapped a minimum 1/2-in and sealed together.

2. A welding strip shall be positioned over the edge of the lap and welded to both pieces of liner. Each end of the welding strip shall extend at least 2-in beyond the liner to provide tabs.

3. Welds shall be tested for tensile strength in accordance with ASTM D412 using Die B. Tensile strength measured across the welded joint shall be at least 2,000 psi.

4. Each welding strip tab, tested separately, shall be subjected to a 10-pound pull normal to the face of the liner with the liner secured firmly in place. There shall be no separation between the welding strip and liner.

5. Three test specimens shall be cut from the welding sample and tested in tension across the welds.

6. If none of the specimens fails when tested as described above, the weld will be considered satisfactory. If one specimen fails to pass the tension test, a retest will be permitted. The retest shall consist of testing three additional specimens cut from the original welded sample. If all three of the retest specimens pass the test, the weld will be considered satisfactory. If two of three specimens fail, the welder will be considered to be an unqualified welder and shall be disqualified.

7. A disqualified welder may submit a new welding sample when he has had sufficient off-the-job training or experience to warrant re-examination. Such training or experience may only be deemed adequate by the Engineer or Owner.

D. Shop holiday testing. Prior to preparing the sheets for shipment, the sheets shall be tested for pinholes using an electrical spark tester set at 20,000 volts minimum. Any holes shall be repaired and retested.

PART 2 PRODUCTS

2.1 MATERIALS

A. All PVC liner materials shall be ultraviolet stabilized.

B. Joint and welding strips shall have the same corrosion resistance as the PVC sheet lining material.

C. All PVC sheet liner sheets, including associated welding strips and accessory items, shall be a combination of polyvinyl chloride resin, pigments and plasticizers, specially compounded to remain flexible and shall be white in color. The polyvinyl chloride resin shall constitute not less than 99 percent by weight of the resin used in the formulation. Copolymer resins will not be permitted.

D. The PVC sheet liner cast integrally with concrete shall be Ameron T-Lock as manufactured by Ameron Protective Lining Products, Brea, CA, or approved equal.

Bid Set April 2017



1. Sheets shall be a minimum of 0.065-in in thickness.

2. T-shaped locking extensions of the same material as the liner sheet shall be integrally extruded with the sheet. Locking extensions shall be approximately 2.5- in apart and shall be at least 0.375-in high.

E. PVC sheet liner installed in mastic over existing concrete shall be Arrow-Lock sheet Lining System as manufactured by Ameron Protective Lining Products, Brea, CA, or approved equal. It shall include a primer, two-component epoxy mastic and extruded PVC liners with locking extensions. Primer for use prior to application of intermediate layer shall be Arrow-Lock Mastic Primer No. 5101. Mastic for intermediate layer shall be Arrow-Lock Mastic No. 9912 2:1 epoxy gel mastic.

1. Sheets shall be a minimum of 0.065-inch in thickness.

2. Locking extensions (arrow-shaped) of the same material as the liner sheet shall be integrally extruded with the sheet. Locking extensions shall be approximately 2-in apart and shall be approximately 0.25-in high.

3. Sheets shall have a nominal width of 48-in and a length of not more than 96-in.

Lengths specified shall include tolerance at a ratio of +/- 1/4-in for each 100-in.

F. All PVC sheet liner sheets, including locking extensions and joint, corner and welding strips, shall be free of cracks, cleavages or other defects adversely affecting the protective characteristics of the materials. The engineer may authorize the repair of such defects by approved methods.

G. All PVC sheet liner shall have the following physical properties when tested at 77°F +/- 5°F:

Table 1

Property ASTM test method

Initial After 112 days chemical exposure

Tensile strength ASTM D412 2,200 psi minimum 2,100 psi minimum

Elongation at break ASTM D412 200% minimum 200% minimum

Shore durometer, Type D (with

respect to initial test result)

ASTM D2240 1-sec: 50-60

10-sec: 35-50

+/- 5%

+/- 5%

Weight change

+/- 1.5%

NOTES: (1) Tensile specimens shall be prepared and tested in accordance with ASTM

D412 using Die B. (2) Weight change specimens shall be 1-in by 3-in samples.

Bid Set April 2017



(3) Specimens for testing of initial properties may be taken from liner sheet and welding strip at any time prior to final acceptance of work.

(4) Continuous locking extensions embedded in concrete shall withstand a test pull of at least 100 pounds per linear inch applied perpendicularly to the concrete surface for a duration of one minute without rupturing the locking extensions or withdrawal from embedment. The test shall be at a temperature of 70°F to 80°F inclusive.

(5) Continuous locking extensions embedded in mastic shall withstand a test pull of at least 20 pounds per linear inch applied perpendicularly to the concrete surface for a duration of one minute without rupturing the locking extensions or withdrawal from the intermediate mastic layer or delamination of the mastic from the concrete substrate. The test shall be at a temperature of 70°F to 80°F inclusive and not before the mastic has cured at least 7 days.

H. After conditioning to constant weight at 110 degrees F, tensile specimens and weight change specimens shall be exposed to the following solutions for a period of 112 days at 77 degrees F +/- 5 degrees F. At 28-day intervals, tensile specimens and weight change specimens shall be removed from each of the chemical solutions and tested in accordance with Table 1, notes 1-3. If any specimen fails to meet the 112-day requirement before completion of the 112-day exposure, the material will be subject to rejection.

Table 2

Chemical solution Concentration

Sulfuric acid

20% *

Sodium hydroxide 5%

Ammonium hydroxide 5% *

Nitric acid 1% *

Ferric chloride 1%

Sodium hypochlorite 1%

Soap 0.1%

Detergent 0.1%

Bacteriological BOD not less than 700 ppm

NOTES: (1) This is to be used as a pre-qualification test and when material

formulations are changed. (2) * Volumetric percentages of concentrated C.P. grade reagents.

Bid Set April 2017



PART 3 EXECUTION

3.1 GENERAL

A. Coordinate the installation of the PVC liner system with the other items of work required for the project.

B. Installation of the lining, including preheating of sheets in cold weather and the welding of

all joints, shall be done in accordance with the manufacturer’s recommendations.

C. The lining installation and sealing shall provide a continuous PVC lining and prevent entrance of concrete or mortar between the lining and the forms. Coverage of the lining shall not be less than the minimum shown on the Drawings.

D. The lining shall be held snugly in place against inner forms where applicable.

E. Locking extensions shall terminate not more than 1.5 inches from the end of the inside surface of the section. Joint flaps when used shall extend approximately 4 inches beyond the end of the inside surface.

F. Using manufacturer recommended joints, connect PVC sheet liner cast integrally with concrete to PVC sheet liner installed in mastic over existing concrete.

G. Using manufacturer recommended joints, connect new PVC sheet liner to existing PVC sheet liner from existing NCOS or junction structure manhole.

H. Unless otherwise shown, the lining shall be returned 4 inches at the surface of the contact between the concrete structure and items not of concrete (including manhole frames, gate guides, clay pipe, or brick manholes, and clay or cast iron pipes). The same procedure shall be followed at joints where the type of protective lining is changed or the new work is built to join existing unlined concrete. At each return, the returned liner shall be sealed to the item in contact with the plastic-lined concrete using Amer-plate adhesive system, or equal. If the liner cannot be sealed with this adhesive because the joint at the return is too wide or rough or because of safety regulations, the joint space shall be densely caulked with lead wool or other approved caulking material to a depth of 2 inches.


A. The Contractor shall take all reasonable precautions during the receipt, handling, and storage of the liner to prevent scratching, denting, or puncturing the liner surface or damaging the anchorage system.

B. Sheets shall be stored in a flat position.

C. During cold weather special precautions shall be made for handling and liner shall be located inside a structure suitable for storage as determined by the Engineer.

D. Protect installed lining from damage from other items of work until final acceptance by

the Owner.

Bid Set April 2017



3.3 PVC SHEET LINER CAST INTEGRALLY WITH CONCRETE INSTALLATION

A. Liner sheets for wall linings shall be closely fitted and properly secured to the concrete contact faces of the forms, which form the surfaces to be lined. Sheets shall be cut to fit curved and warped surfaces using a minimum number of separate pieces. If liner joints are to be joined as specified herein, the adjacent pieces shall be overlapped or butted with not more than 1/8-in opening between the joints. The sheets shall be placed with the smooth face next to the form and the line of tees or anchoring devices on the back side of the sheets vertically in the walls. After all sheets are in place on the form being lined, the joints between sheets shall be sealed on the back side to prevent concrete from flowing around edges. Sealing shall be accomplished with a 1-in wide welding strip or other means acceptable to the Engineer. A termination strip shall be provided at the intersection of the walls and slab.

B. Where possible, the form to be lined shall be set in place, the lining attached, and all lining joints covered before the reinforcing steel is installed. The outer form shall then be set in place and the form ties installed through the liner in the normal manner. The number of form ties used shall be kept to a minimum.

C. Concrete poured against lining shall be vibrated, spaded or compacted in a careful

manner so as to protect the lining and produce a dense, homogenous concrete, securely anchoring the locking extensions into the concrete.

D. In removing forms, exercise care to protect the lining from damage. Sharp instruments shall not be used to pry forms from lined surfaces. When forms are removed, any nails that remain in the lining shall be pulled without tearing the lining, and the resulting holes shall be clearly marked.

E. All nail and tie holes and all cut, torn and heavily abraded areas in the lining shall be patched. Patches made entirely with welding strip shall be fused to the liner over the patch area. Larger patches may consist of smooth liner sheet applied over the damaged area with adhesive. All edges shall be covered with welding strip fused to the patch and the sound lining adjoining the damaged area.

F. After the forms have been removed, the exposed butt joints in the liner, including nail and form tie holes, shall be sealed with welding strip heat-welded over the areas involved. Sealing shall provide a continuous PVC lining.

G. Liner sheets for ceiling surfaces shall be set, properly secured, and joints sealed in

accordance with the requirements specified for wall surfaces. Care shall be taken to form and securely seal the corners formed between the wall and ceiling sheets.

H. Wrapping. Underneath slabs or along walls where an opening, such as an access opening, is indicated on the drawings, the liner shall be wrapped or placed along the opening ledge or exposed vertical section of concrete.

I. Wherever pipe or cast-in-place structures protected with lining join structures no so lined, the lining shall be extended over and around the end of the pipe and back in the structure for not less than 4-in. The protecting cap may be molded or fabricated from the lining material but need not be locked into the pipe.

Bid Set April 2017



J. Where a pipe lateral (not of PVC-line concrete) is installed through lined concrete pipe, the seal between the lined portion and the lateral shall be made by the method prescribed as detailed in the Drawings or as recommended by the manufacturer.

K. Liner sheets shall be closely fitted and properly secured to the inner forms. Sheets shall be cut to fit curved and warped surfaces using a minimum number of separate pieces.

L. Unless otherwise shown on the plans, the lining shall be returned at least 3-in at the surfaces of contact between the concrete structure and items not of concrete (including manhole frames, gate guides, clay pipe or brick manholes and clay or cast iron pipes). The same procedure shall be followed at joints where the type of protective lining is changed or the new work is built to join existing unlined concrete. At each return, the returned liner shall be sealed to the item in contact with the plastic-lined concrete using Ameron T-Lock 19Y adhesive system. If the liner cannot be sealed with this adhesive because of the joint at the return being too wide or rough or because of safety regulations, the joint space shall be densely caulked with lead wool or other approved caulking material to a depth of 2-in and finished with a minimum of 1-in of an approved corrosion resistant material.

M. Liner sheeting, except where indicated otherwise, shall have integral locking extensions. The liner shall be mechanically and permanently embedded in the concrete. Where liner with PVC sheet liner T-Lock ribbing cannot be installed, use PVC sheet liner installed in mastic over existing concrete.

N. Lining at joints shall be free of all mortar and other foreign material and shall be clean

and dry before joints are made.

O. Field joints in the lining shall be of the following described types, used as prescribed:

1. Type C-1: The joint shall be made with a separate 4-inch joint strip and two welding strips. The 4-inch joint strip shall be centered over the joint, heat-sealed to the liner then welded along each edge to adjacent sheets with a 1-inch wide welding strip. The width of the space between adjacent sheets shall not exceed 2 inches. The 4-inch joint strip shall lap over each sheet a minimum of 1/2 inch. It may be used at any transverse or longitudinal joint.

2. Type C-2: The joint shall be made by lapping sheets not less than 1/2 inch. One 1- inch wide welding strip is required. The upstream sheet shall overlap the one downstream. The lap shall be heat-sealed into place prior to welding on the 1-inch welding strip.

3. Type C-3: The joint shall be made by applying 2-inch wide waterproof tape or 1- inch wide welding strip on the back of the maximum 1/4-inch gap butt joint or by some other method approved by the Engineer to prevent wet concrete from getting under the sheet. After the forms have been stripped, a 1-inch welding strip shall be applied over the face of the sheet.

Bid Set April 2017



3.4 PVC SHEET LINER INSTALLED IN MASTIC OVER EXISTING CONCRETE INSTALLATION

A. Prior to primer application, clean concrete substrate to receive PVC sheet liner of contaminants such as dust, oil, dirt, and corrosion residues by water blasting or mechanical abrasion.

B. Confirm the pH range for the prepared surface is 7 or greater.

C. Roughen existing concrete surface to ICRI 03732 Concrete Surface Profile (CSP) 3 in accordance with the manufacturer’s recommendations.

D. Confirm the concrete substrate is adequately dry to receive the primer and mastic using manufacturer recommended procedures.

E. Prepare substrate cracks, areas requiring resurfacing and perform detail treatment per

manufacturer recommendations.

F. Install liner, including preheating of sheets in cold weather and the welding of all joints, in accordance with the manufacturer’s recommendations.

G. The lining is normally installed with the locking extensions running vertically in the structure. All cut, torn and heavily abraded areas in the lining shall be patched according to the manufacturer’s instructions.

H. Field joints in the lining shall be of the following described types, used as prescribed:

1. Type AL-1: The joint shall be made with a separate 4-inch joint strip. The spacing between the two lining sheets to be joined shall not exceed 1 inch. A 1-in weld strip shall be fuse-welded on each side of the 4-in wide joint strip in accordance with the manufacturer’s instructions.

2. Type AL-2: The joint shall be made with a 1-inch wide weld strip. The two lining sheets to be joined shall be overlapped a minimum of 1/2-inch. The upstream sheet shall overlap the one downstream (if applicable). The lap shall be heat- sealed into place prior to fuse welding on the 1-in wide weld strip.

3. Type AL-3: The joint shall be made with a 1-inch wide weld strip. The two lining

sheets to be joined shall be aligned with a 1/4-inch maximum gap between the sheets. The weld strip shall be centered over the gap and hot-air fuse-welded according to the manufacturer’s instructions.

3.5 TESTING AND REPAIRING DAMAGED SURFACES

A. After the PVC liner system is installed, all surfaces covered with lining, including welds, shall be visually inspected for integrity of welds and lining surfaces. The surface of the liner shall be cleaned as required to permit visual inspection and spark testing.

B. The installed PVC liner shall meet the following strength test requirements:

Bid Set April 2017



1. The test pull specified in the APWA Specifications shall be performed in the presence of the Engineer on a minimum of one lined section for each 100 square feet of liner. The test shall be performed on a liner section selected by the Engineer. The pull test of the liner shall be performed on a one inch to three inch length of tee. Unless otherwise directed by the Engineer, the location of the tests shall be within two feet of the end of the section except that a minimum distance between the test location and the end of the sheet shall be six inches.

2. The Contractor shall submit his proposed method of making the pull test to the

Engineer for his approval prior to conducting the test.

3. In the event that one section of liner fails to withstand the required test, the Contractor shall have the right to perform the test on the liner in two other sections selected by the purchaser from the same run from which the original liner was selected. If these two sections successfully pass the test, the remainder of the liner that section will be accepted. If tests of either of these sections fail, the remainder of that section will not be accepted until a pull test of the liner in each of the sections has satisfactorily passed the test. Locations of the additional pull tests shall be determined by the Engineer.

4. The liner in the test section which passes the pull test shall be repaired by fusion

welding and shipped to the project site.

5. The Engineer may require additional pull tests if visual inspection reveals bumps or imperfections that may indicate improper embedment of the liner.

C. After liners are installed in structures and after a lined pipe is installed and backfilled prior to hydrostatic testing, all surfaces covered with lining, including welds, shall be tested at the expense of the Contractor, with an acceptable electrical spark tester with the instrument set at 20,000 volts. All holes shall be repaired and retested.

D. All welds shall be physically tested by a nondestructive proving method using a blunt instrument such as a putty knife.

E. Any loose joints, punctures or tears in the lining shall be repaired using methods

approved by the lining manufacturer.

3.6 INSTALLATION SCHEDULE

A. PVC liner system shall be installed on the following concrete surfaces:

Table 3

Location Surface to be covered

PVC liner

Junction structure Ceiling Type A

Junction structure Walls Type A

Bid Set April 2017



Junction structure Exposed surfaces of

existing NCOS roof including from

access hole cut

Type B

NOTES:

(1) Type A - PVC sheet liner cast integrally with concrete

(2) Type B - PVC sheet liner installed in mastic over existing concrete

END OF SECTION

Bid Set April 2017




Bid Set April 2017

Concrete Formwork 03100 - 1


SECTION 03100

CONCRETE FORMWORK

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and design, install and remove formwork for cast-in-place concrete complete as shown on the Drawings and as specified herein.

B. Secure to forms or set for embedment all miscellaneous metal items, sleeves, reglets, anchors, inserts, waterstops, hatches and other items furnished under other Sections and required to be cast into concrete.

1.2 RELATED WORK

A. Plastic lining for cast-in-place concrete is included in Section 02766.

B. Concrete reinforcement is included in Section 03200.

C. Concrete joints and joint accessories are included in Section 03250.

D. Cast-in-place concrete is included in Section 03300.

E. Concrete finishes are included in Section 03350.

F. Grout is included in Section 03600.

G. Modifications to existing concrete are included in Section 03740.

H. Miscellaneous metals are furnished under Section 05500.

1.3 SUBMITTALS

A. Submit, in accordance with Section PR-9, shop drawings and product data showing materials of construction and details of installation for:

1. Form release agent

2. Form ties

B. Review will be for appearance, performance and strength of the completed structure only. Approval by the Engineer will not relieve the Contractor of responsibility for the strength, safety or correctness of methods used, the adequacy of equipment, or from carrying out the work as shown on the Drawings and as specified herein.

Bid Set April 2017



C. Sample Substrate

1. Demonstrate to the Engineer on a designated area of the concrete substructure exterior surface that the form release agent will not impair the bond of paint, sealant, waterproofing, dampproofing, or other coatings and will not affect the forming materials.

D. Certificates

1. Submit completed PE Certification Form for design of formwork in accordance with Section PR-9. The PE Certification Form shall be completed and stamped by a professional engineer registered in the State of California.

2. Certify that form release agent complies with Federal, State and local VOC limitations.


A. American Concrete Institute (ACI)

1. ACI 301 - Specifications for Structural Concrete

2. ACI 318 - Building Code Requirements for Structural Concrete

3. ACI 347 - Guide to Formwork for Concrete

B. APA - The Engineered Wood Association (APA)

1. Material grades and designations as specified



A. Structural design responsibility: Contractor shall provide all forms and shoring designed by a professional engineer registered in the State of California. Design formwork in accordance with the requirements of ACI 301, ACI 318 and ACI 347. Comply with all applicable regulations and codes. Consider any special requirements due to the use of plasticized and/or retarded set concrete.

PART 2 PRODUCTS

2.1 GENERAL

A. The usage of a manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configurations desired.

Bid Set April 2017



2.2 MATERIALS

A. Forms, General

1. Make forms for cast-in-place concrete of wood, steel or other approved materials, except as specified in Paragraphs 2.02B and 2.02C. Construct wood forms of sound lumber or plywood free from knotholes and loose knots. Construct steel forms to produce surfaces equivalent in smoothness and appearance to those produced by new plywood panels. Design and construct all forms to provide a flat, uniform concrete surface requiring no grinding, repairs, or finishing except as specified in Section 03350.

B. Forms for Exposed Concrete

1. Make forms for all exposed and non-submerged exterior and interior concrete of new and unused plyform exterior grade plywood panels manufactured in compliance with the APA and bearing the APA trademark. Provide B grade or better veneer on all faces to be in contact with concrete. Design and construct all forms to provide a flat, uniform concrete surface requiring no grinding, repairs, or finishing except as specified in Section 03350.

2. Provide rigid forms that will not deflect, move, or leak. Design forms to withstand the high hydraulic pressures resulting from rapid filling of the forms and heavy high frequency vibration of the concrete. Limit deflection to 1/400 of each component span. Lay out form joints in a uniform pattern.

3. Dress and match boards. Sand plywood smooth and fit adjacent panels with tight joints. Tape, gasket, plug, and/or caulk all joints and gaps in forms to provide watertight joints that will withstand placing pressures without exceeding specified deflection limit or creating surface patterns.

4. Provide ¾-inch chamfer on all corners exposed to view unless otherwise indicated.

C. Column Forms

1. Form rectangular columns as specified for exposed concrete. Provide 3/4-in chamfer on all corners unless otherwise indicated.

D. Mill and plane smooth moldings for chamfers. Provide chamfer strips of nonabsorbent material, compatible with the form surface and fully sealed on all sides to prevent the loss of paste or water between the two surfaces.

E. Form Release Agent. Coat all form surfaces in contact with concrete with an effective, non-staining, non-residual, water based, bond-breaking form coating unless otherwise indicated or specified. Form release agent shall not impair the bond of sealant, liner, waterproofing, dampproofing or other coatings.

F. Form Ties

1. Coil and Wire Ties: Provide ties manufactured so that, after removal of the projecting part, no metal remains within 1-1/2 inches of the face of the concrete.

Bid Set April 2017



The part of the tie to be removed shall be at least ½ inch diameter or be provided with a plastic or wooden cone at least 1/2-inch diameter and 1-1/2 inches long. Provide cone washer type form ties in concrete exposed to view.

2. Flat Bar Ties for Panel Forms: Provide ties that have plastic or rubber inserts with a

minimum depth of 1-1/2 inches and manufactured to permit patching of the tie hole.

3. Do not use common wire for form ties.

4. Provide ties for liquid retaining structures that have a steel waterstop tightly attached to each strut or that have a neoprene rubber washer on each strut.

5. At liquid containing structures, form tie systems other than those requiring integral waterstops may be used. As a minimum, the alternate system shall comply with the following: a. Tapered through-bolts at least 1-in in diameter at smallest end or through- bolts

that utilize a removable tapered sleeve of the same minimum size. The largest end shall be located on the liquid bearing wall face.

b. Coat tapered rubber plug with epoxy bonding agent and insert in form tie hole 2-

in minimum from the liquid bearing wall face.

c. Fill both sides of taper tie hole with non-shrink grout.

d. Obtain Engineer’s acceptance of system and spacing of ties prior to ordering or purchase of forming. +

e. The Contractor shall be responsible for watertightness of the form ties and any

repairs needed. See Section 01480 for watertightness test requirements.

PART 3 EXECUTION 3.1 GENERAL

A. Design, furnish, erect, shore, brace, and maintain formwork for all cast-in-place concrete including sides of footings in accordance with ACI 301, ACI 318, and ACI 347. Construct and place forms to provide concrete of the shape, lines, dimensions and appearance indicated.

B. Provide removable panels at the bottom of forms for walls and columns to allow cleaning, inspection and joint surface preparation. Provide closable intermediate inspection ports in forms for walls. Provide tremies and hoppers for placing concrete and to allow concrete sampling, prevent segregation and prevent the accumulation of hardened concrete on the forms and reinforcement above the fresh concrete.

C. Place molding, bevels, or other types of chamfer strips to produce blockouts or chamfers as indicated on the Drawings or as specified herein. Provide chamfer strips at horizontal and vertical projecting corners to produce a 3/4-in chamfer. Provide

Bid Set April 2017



rectangular moldings at locations requiring sealants where shown on the Drawings or specified herein.

D. Provide rigid forms to withstand construction loads and vibration and meeting specified deflection limits and tolerances. Construct forms so that the concrete will not be damaged by form removal.

E. Accessories which remain embedded in the concrete after formwork removal will be subject to the approval of the Engineer. Permanent embedments shall have sufficient concrete cover or be of suitable materials for the exposure condition as approved by the Engineer. Remove unsatisfactory embedded items at no additional cost to the Owner.

3.2 FORM TOLERANCES

A. Design, construct and surface forms in accordance with ACI 347 and meet the following additional requirements for the specified finishes.

B. Forms for Exposed Concrete: Edges of all form panels in contact with concrete flush within

1/8-in and forms for plane surfaces plane within 1/8 inch 4-ft. Maximum deviation of the finished surface at any point not to exceed 1/4 inch from the intended surface indicated. Arrange form panels symmetrically and orderly to minimize the number of seams. Provide tight forms to prevent the passage of mortar, water, and grout.

C. Formed Surface Buried or Not Exposed to View: Class "C" Surface per ACI 347.

D. Formed Surface Including Mass Concrete, Pipe Encasement, and Other Similar Installations: No minimum requirements for surface irregularities and surface alignment. The overall dimensions of the concrete shall be plus or minus 1 inch from the intended surface indicated.

3.3 FORM PREPARATION

A. Clean, repair, remove projecting nails and fill holes, and smooth protrusions on all form surfaces to be in contact with concrete before reuse. Do not reuse forms for exposed concrete unless a "like new" condition of the form is maintained that will produce surfaces equivalent in smoothness and appearance to those produced by new plywood panels.

B. Coat wood forms in contact with concrete using form release agent prior to form installation.

C. Clean steel forms by sandblasting or other method to remove mill scale and other ferrous deposits from the contact surface of all forms. Coat steel forms in contact with concrete using form release agent prior to form installation.

3.4 REMOVAL OF FORMS

A. Be responsible for all damage resulting from removal of forms and make repairs at no additional cost to the Owner. Leave in place forms and shoring for horizontal structural

Bid Set April 2017



members in accordance with ACI 301 and ACI 347. Conform to the requirements for form removal specified in Section 03300.

3.5 INSPECTION

A. Notify the Engineer when the forms are complete and ready for inspection, at least six working hours prior to the proposed concrete placement. The Engineer will inspect the forms to ensure overall conformance with the contract documents.

B. Failure of the forms to comply with the requirements specified, or to produce concrete complying with requirements specified shall be grounds for rejection of that portion of the concrete work. Repair or replace rejected work as directed by the Engineer at no additional cost to the Owner. Such repair or replacement shall be subject to the requirements of these Specifications and approval of the Engineer.

END OF SECTION

Bid Set April 2017

Concrete Reinforcement 03200 - 1


PART 1 GENERAL

SECTION 03200 CONCRETE REINFORCEMENT

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and install all concrete reinforcement complete as shown on the Drawings and as specified herein.

1.2 RELATED WORK


B. Concrete joints and joint accessories are included in Section 03250.

C. Cast-in-place concrete is included in Section 03300.

D. Grout is included in Section 03600.

E. Modifications to existing concrete are included in Section 03740.

1.3 SUBMITTALS

A. Submit, in accordance with Section PR-9, shop drawings and product data showing materials of construction and details of installation for:

1. Reinforcing steel. Drawings for fabrication, bending, and placement of concrete reinforcement shall conform to the recommendations of ACI 315 for placement drawings and as specified herein.

a. Placement drawings. For walls, show elevations from the outside, looking

towards the structure, at a minimum scale of 1/4-in to one foot. For slabs, show top and bottom reinforcement on separate plan views, as needed for clarity. For beams and columns, show schedules with sections and/or elevations and stirrup/tie spacing. Show additional reinforcement around openings, at corners and at other locations indicated, diagrams of bent bars, arrangements and assemblies, all as required for the fabrication and placement of concrete reinforcement. Reference bars to the same identification marks shown on the bar bending details. Identify bars that will have special coatings and/or to be of special steel or special yield strength.

b. Bar bending details. Reference bars to the same identification marks shown on

the placement drawings. Identify bars to have special coatings and/or to be of special steel or special yield strength.

2. Fiber reinforcement. Submit manufacturer's data for synthetic reinforcing fibers. Identify all placements that are to contain synthetic reinforcing fibers. The fiber length and amount of fibers per cubic yard to be used for each placement shall be noted. Submit two samples of synthetic reinforcing fibers.

Bid Set April 2017



B. Submit samples of each of the following items.

1. Two samples of each type of mechanical reinforcing steel coupling system.

C. Submit, in accordance with Section PR-9, Test Reports of each of the following items.

1. Certified copy of mill test on each heat of each steel proposed for use showing the physical properties of the steel and the chemical analysis.

2. Welder's certification in accordance with AWS D1.4 when welding of reinforcement is indicated, specified, or approved.

3. Certified copy of test reports for each foreign manufactured steel proposed for use in the fabrication of reinforcement. The tests shall be specifically made for this project at the expense of the Contractor by a domestic independent testing laboratory certified to perform the tests. The testing shall be for conformity to the applicable ASTM Standard.



1. ASTM A82 - Standard Specification for Steel Wire, Plain, for Concrete Reinforcement.

2. ASTM A185 - Standard Specification for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement.

3. ASTM A497 - Standard Specification for Steel Welded Wire Fabric, Deformed, for Concrete Reinforcement.

4. ASTM A615 - Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement.

5. ASTM A704 - Standard Specification for Welded Steel Plain Bar or Rod Mats for Concrete Reinforcement.

6. ASTM A706 - Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement.


1. ACI 301 - Specifications for Structural Concrete.

2. ACI 315 - Details and Detailing of Concrete Reinforcement.

3. ACI 318 - Building Code Requirements for Structural Concrete.

4. SP-66 (ACI 315) ACI Detailing Manual.

Bid Set April 2017



C. Concrete Reinforcing Steel Institute (CRSI)

1. Manual of Standard Practice

D. American Welding Society (AWS)

1. AWS D1.4 Structural Welding Code - Reinforcing Steel



A. Fiber Reinforcement. Provide services of a manufacturer's representative, with at least 2 years’ experience in the use of the synthetic reinforcing fibers for a preconstruction meeting and assistance during the first placement of the material.

1.6 DELIVERY, HANDLING AND STORAGE

A. Provide reinforcement free from mill scale, rust, mud, dirt, grease, oil, ice, or other foreign matter.

B. Ship and store reinforcement with bars of the same size and shape fastened in bundles with durable tags, marked in a legible manner with waterproof markings showing the same "mark" designations as those shown on the submitted placement drawings. Tags for ASTM A706 reinforcing and for ASTM A615 reinforcing meeting the requirements of Paragraph 2.01C.1 shall indicate that the reinforcing is weldable.

C. Store reinforcement off the ground, protect from moisture and keep free from rust, mud, dirt, grease, oil, ice, or other injurious contaminants.

PART 2 PRODUCTS

2.1 MATERIALS

A. Provide new materials complying with the following material specifications.

B. Deformed Concrete Reinforcing Bars: ASTM A615 or ASTM A706, Grade 60 deformed bars.

C. Deformed Concrete Reinforcing Bars required on the Drawings to be Field Bent or Welded: ASTM A706.

1. ASTM A615, Grade 60 may be substituted for ASTM A706 subject to the following:

a. The actual yield strength of the reinforcing steel based on mill tests does not

exceed the specified yield strength by more than 18,000 psi. Retests shall not exceed this value by more than an additional 3,000 psi.

Bid Set April 2017



b. The ratio of the actual ultimate tensile strength to the actual tensile yield strength of the reinforcement is not less than 1.25.

c. The carbon equivalency (CE) is 0.55 percent or less.

D. Welded Steel Wire Fabric: ASTM A1064.

E. Reinforcing Steel Accessories

1. Plastic Protected Wire Bar Supports: CRSI Bar Supports, Class 1 - Maximum Protection.

2. Stainless Steel Protected Wire Bar Supports: CRSI Bar Supports, Class 2 - Moderate Protection with legs made wholly from stainless steel wire.

3. Precast Concrete Bar Supports: CRSI Bar Supports, Precast Concrete Bar Supports. Precast concrete blocks that have equal or greater strength than the surrounding concrete.

F. Tie Wire

1. Tie Wires for Reinforcement: 16-gauge or heavier black annealed wire.

G. Mechanical Reinforcing Steel Coupling System

1. Use only where indicated. Mechanical reinforcing steel coupling system shall be positive connecting taper threaded type employing a hexagonal coupler such as Lenton rebar splices as manufactured by Erico Products Inc., Solon, OH or equal. Coupling system shall meet all ACI 318 requirements. Bar ends must be taper threaded with coupler manufacturer's bar threader to ensure proper taper and thread engagement. Furnish cap on female end to exclude dirt, debris and wet concrete. Couplers shall be torqued to manufacturer's recommended value.

2. Unless otherwise noted on the Drawings, mechanical reinforcing steel coupling system shall produce a splice strength in tension or compression of not less than 125 percent of the ASTM specified minimum yield strength of the reinforcing bar. Base yield strength on Grade 60 reinforcing unless otherwise indicated or specified.

3. Compression type mechanical splices shall provide concentric bearing from one bar to the other bar.

H. Fiber Reinforcement

1. Synthetic reinforcing fibers for concrete grout shall be 100 percent polypropylene collated, fibrillated fibers, Fibermesh 300 as manufactured by Propex Concrete Systems Corp, Chattanooga, TN, or equal. Fiber length and quantity for the concrete grout mix shall be in strict compliance with the manufacturer's recommendations as approved by the Engineer.

Bid Set April 2017



2.2 FABRICATION

A. Comply with the CRSI Manual of Standard Practice.

B. Bend bars cold. Do not straighten or rebend bars.

C. Bend bars around a revolving collar having a diameter not less than that recommended by the CRSI or ACI 318.

D. Saw cut bar ends that are to be butt spliced, placed through limited diameter holes in metal, or threaded. Terminate saw cut ends in flat surfaces within 1-1/2 degrees of a right angle to the axis of the bar.

PART 3 EXECUTION

3.1 INSTALLATION

A. Comply with the CRSI Manual of Standard Practice for surface condition, bending, spacing and tolerances of placement for reinforcement. Provide the amount of reinforcing indicated at the spacing and clearances indicated on the Drawings.

B. Determine clear concrete cover based on exposure to the environment. Unless

indicated otherwise on the Drawings, provide the following minimum clear concrete cover over reinforcement:

1. Concrete cast against and permanently exposed to earth: 3-inches

2. Concrete exposed to soil, water, sewage, sludge and/or weather:

a. Slabs (top and bottom cover), walls: 2 inches

b. Beams and columns (ties, spirals and stirrups): 2 inches

3. Concrete not exposed to soil, water, sewage, sludge and/or weather:

a. Slabs (top and bottom cover), walls, joists, shells and folded plate members: 1 inch

b. Beams and columns (ties, spirals and stirrups): 1-1/2 inches

C. Coat uncoated reinforcement which will be exposed for more than 60 days after placement with a heavy coat of neat cement slurry.

D. Do not weld reinforcing steel bars either during fabrication or erection unless indicated on the Drawings or as specified herein, or unless prior written approval has been obtained from the Engineer. Remove immediately all bars that have been welded, including tack welds, without such approval. Comply with AWS D1.4 when welding of reinforcement is shown on the Drawings, specified, or approved.

E. Reinforcing steel interfering with the location of other reinforcing steel, piping, conduits or embedded items may be moved within the specified tolerances or one bar diameter, whichever is greater. Obtain the approval of the Engineer if greater displacement of

Bid Set April 2017



bars to avoid interference is needed. Do not cut reinforcement to install inserts, conduits, mechanical openings or other items without the prior approval of the Engineer.

F. Secure, support and tie reinforcing steel to prevent movement during concrete

placement. Secure dowels in place before placing concrete.

G. Do not field bend reinforcing unless indicated or specifically authorized in writing by the Engineer. Cold-bend bars indicated or authorized to be field bent around the standard diameter spool specified in the CRSI. Do not heat bars. Closely inspect the reinforcing steel for breaks. Replace, repair by cutting out damaged bars and splicing new bars using coupling sleeves filled with ferrous material, or otherwise repair damaged reinforcing bars as directed by the Engineer at no additional cost to the Owner. Do not bend reinforcement after it is embedded in concrete unless indicated on the Drawings.

3.2 REINFORCEMENT AROUND OPENINGS

A. Provide additional reinforcing steel on each side of the opening equivalent to one half of the cross-sectional area of the reinforcing steel interrupted by the opening unless indicated otherwise on the Drawings. Extend each end of each bar beyond the edge of the opening or penetration by the tension development length for that bar size.

3.3 SPLICING OF REINFORCEMENT

A. Provide splices as shown on the Drawings and as specified herein.

B. Splices Indicated as Compression Splices: Provide lap splice of 30 bar diameters, but not less than 12-in unless indicated otherwise on the Drawings. Base the lap splice length for column vertical bars on the bar size in the column above.

C. All Other Splices: Provide tension lap splices in compliance with ACI 318. Stagger splices in adjacent bars where possible. Provide Class B tension lap splices at all locations unless otherwise indicated.

D. Lap splices in welded wire fabric in accordance with the requirements of ACI 318 but not less than 12-in. Tie the spliced fabrics together with wire ties spaced not more than 24 inches on center and lace with wire of the same diameter as the welded wire fabric. Offset splices in adjacent widths to prevent continuous splices.

E. Mechanical reinforcing steel coupling system shall be used only where shown on the Drawings. Offset splices in adjacent bars by at least 30 bar diameters. Mechanical reinforcing steel coupling system is only to be used for special splice and dowel conditions approved by the Engineer.

F. After installation of mechanical reinforcing steel coupling system, on reinforcement, repair coating damage in accordance with the applicable ASTM standard. Coat all parts of mechanical connectors used on coated bars including steel splice sleeves, bolts and/or nuts with the same material used for the repair of damaged coating.

Bid Set April 2017



3.4 ACCESSORIES

A. Determine, provide and install accessories such as chairs, chair bars and the like to support the reinforcement providing the spacing and clearances indicated on the Drawings and prevent its displacement during the erection of the reinforcement and the placement of concrete.

B. Use precast concrete blocks where the reinforcing steel is to be supported over soil.

C. Use plastic protected bar supports or steel supports with plastic tips where the reinforcing steel is to be supported on forms for a concrete surface that will be exposed to weather, high humidity, or liquid (including bottom of slabs over liquid containing areas). Use stainless steel protected bar supports in walls, beams and elevated slabs. Use stainless steel supports or plastic tipped metal supports in all other locations unless otherwise noted on the Drawings or specified herein.

D. Provide #5 minimum size support bars. Do not reposition upper bars in a bar mat for use as support bars.

E. Alternate methods of supporting top steel in slabs, such as steel channels supported on the bottom steel or vertical reinforcing steel fastened to the bottom and top mats, may be used if approved by the Engineer.

3.5 INSPECTION

A. Notify the Engineer when the reinforcing is complete and ready for inspection, at least six working hours prior to the proposed concrete placement. Do not cover reinforcing steel with concrete until the installation of the reinforcement, including the size, spacing and position of the reinforcement has been inspected by the Registered Deputy Inspector and the Engineer's release to proceed with the concreting has been obtained. Keep forms open until the Registered Deputy Inspector has completed inspection of the reinforcement.

END OF SECTION

Bid Set April 2017




Bid Set April 2017

Concrete Joints and Joint Accessories 03250 - 1


SECTION 03250

CONCRETE JOINTS AND JOINT ACCESSORIES

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and install accessories for concrete joints complete as shown on the Drawings and as specified herein.

1.2 RELATED WORK

A. Water-tightness test for water containing structures is included in Section 01480.

B. Concrete formwork is included in Section 03100.

C. Concrete reinforcement is included in Section 03200.


E. Concrete finishes are included in Section 03350.

F. Grout is included in Section 03600.

G. Modifications to existing concrete are included in Section 03740.

H. Miscellaneous metals are included in Section 05500.

I. Dampproofing is included in Section 07110.

1.3 SUBMITTALS

A. Submit, in accordance with Section PR-9, shop drawings and product data for:

1. Plastic Waterstops: Product data including sample, catalogue cut, dimensions, technical data, storage requirements, splicing methods, conformity to CRD standards, detailed drawings and samples of factory fabrications.

2. Special Waterstops: Product data including location of use, sample, catalogue cut, technical data, storage requirements, splicing methods, installation instructions, and conformity to CRD, ASTM or FS standards, as applicable.

a. Injectable Waterstop Hose System: In addition to the requirements specified

above: Submit applicator certification by manufacturer of injectable waterstop hose system. Submit manufacturer's specifications for cleaning and preparing surfaces to receive waterstop system and instructions for installation and injection. Include manufacturer product data confirming that materials are recommended for applications indicated on the Drawings and recommendations for inspection. Submit installation drawings showing layout, injection locations and details of injectable waterstop hose system.

Bid Set April 2017



3. Premolded joint fillers: Product data including location of use, sample, catalogue cut, technical data, storage requirements, installation instructions, and conformity to ASTM standards.

4. Bond breaker: Product data including location of use, catalogue cut, technical

data, storage requirements, and application instructions.

5. Sealant: Product data including location of use, catalogue cut, technical data, storage requirements, mixing and application instructions, and conformity to ASTM standards.

B. Shop Drawings

1. Waterstop placement (layout) drawings including shop-made fitting details.

C. Certifications

1. Certify that all materials used within the joint system are compatible with each other.



1. ASTM C309 - Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete.

2. ASTM C920 - Standard Specification for Elastomeric Joint Sealants.

3. ASTM D746 - Standard Test Method for Brittleness Temperature of Plastics and Elastomers by Impact.

4. ASTM D1752 - Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion Joint Fillers for Concrete Paving and Structural Construction.

B. U.S. Army Corps of Engineers (CRD).

1. CRD C572 - Specification for Polyvinylchloride Waterstops.



A. Provide services of a manufacturer's field representative of the sealant who has performed at least five projects of similar size and complexity within the last 5 years. The field representative shall be present at the work site prior to any mixing of components to instruct on mixing, application and inspection procedures and to inspect the finish of the prepared surfaces prior to application of the sealant.

Bid Set April 2017



B. The manufacturer's field representative shall make at least one additional visit to the site as the work progresses and shall report on each visit to the Contractor and the Engineer, advising as to whether the application is being performed in accordance with this Section and the manufacturer's printed instructions.

C. Injectable waterstop hose system shall be installed by an applicator certified by the manufacturer.


A. Deliver products in original, unopened containers displaying the manufacturer's label showing manufacturer name, product identification and batch number.

B. Store products as recommended by the manufacturer. PART 2 PRODUCTS

2.1 GENERAL

A. All materials used together in a given joint shall be compatible with one another. Coordinate selection of suppliers and products to provide compatibility. Do not use asphaltic bond breakers or asphaltic joint fillers in joints receiving sealant.

B. The injectable waterstop hose system shall consist of products specifically manufactured for the purpose for which they will be used and the products shall have been successfully used in similar applications for more than five years.

2.2 MATERIALS

A. Plastic Waterstops

1. Waterstops for non-expansion joints and other locations shown on the Drawings: 6 inches by 3/8 inch ribbed type waterstops conforming to CRD C572 and made by extruding elastomeric plastic compound with virgin polyvinylchloride as the basic resins. The compound shall contain no reprocessed materials. Minimum tensile strength of waterstop 1750 psi. Waterstops shall incorporate an integral fastening system, or be provided with grommets or prepunched holes between the outermost ribs at a spacing of 12 inches on center. Waterstops shall be style FR- 6380 by Paul Murphy Plastics Co., Roseville, MI; style 679 by Greenstreak Plastic Products, St. Louis, MO; style R6-38 by Vinylex Corp., Knoxville, TN, or equal.

2. Factory fabrications: provide factory fabrications for all waterstop changes of direction, transitions, and intersections (vertical ells, flat ells, vertical tees, flat tees, vertical crosses, flat crosses, and special, unusual or complicated intersections including intersections of waterstops of different sizes or configurations, and intersections due to joint offsets). Factory fabrications shall be made and inspected by the waterstop manufacturer. Provide stubends of sufficient length to leave only straight butt joints for splicing in the field.

Bid Set April 2017



B. Special Waterstops

1. PVC Retrofit Waterstops for non-expansion joints: "L" type waterstop conforming to CRD C572 and made by extruding elastomeric plastic compound with virgin polyvinylchloride as the basic resins. The compound shall contain no reprocessed materials. Minimum tensile strength of waterstop 1750 psi. Waterstop shall be style 581, complete with Type 304 stainless steel batten bars and 1/4-inch diameter stainless steel expansion bolts, by Greenstreak Plastic Products, St. Louis, MO or equal.

2. Injectable Waterstop Hose System for non-expansion joints where shown on the Drawings:

a. The injectable waterstop hose system shall be comprised of a hose utilizing a

spiral core enclosed within an exterior membrane, injectable grout/resin, anchoring clips, packers and all other accessories necessary for a complete injectable waterstop hose system. Injectable waterstop hose system shall be Injecto Tube with Hydro Active Injecto Grout manufactured by De Neef Construction Chemicals, Inc., Houston, TX, Duroject Injection Hose with Multigel 850 Injection Resin manufactured by BBZ USA, Inc., Southington, CT; or equal.

C. Premolded Joint Filler

1. Premolded Joint Filler – Structures: Self-expanding cork premolded joint filler conforming to ASTM D1752, Type III. Provide 1-in thickness unless otherwise indicated on the Drawings.

D. Bond Breaker

1. Bond Breaker Tape: Adhesive-backed glazed butyl or polyethylene tape which will adhere to the premolded joint filler or concrete surface. Provide tape the same width as the joint.

2. Bond breaker for concrete other than where tape is indicated on the Drawings or

specified: Either bond breaker tape or a non-staining type bond prevention coating such as Crete-Lease Bond Breaker for Tilt-Up by Cresset Chemical Co.; Sure-Lift J-6 WB by Dayton Superior; Silcoseal Select by Nox-Crete, or equal.

3. Bond breaker for expansion joint dowels: Water based white pigmented curing compound conforming to ASTM C309, Type 2, Class A.

E. Sealant

1. Provide sealant for joints in horizontal surfaces conforming to ASTM C920, Type S or M, Grade P or NS, Class 25. Provide sealant for joints in sloping and vertical surfaces conforming to ASTM C920, Type S or M, Grade NS, Class 25. Provide Use T sealant in pedestrian and vehicular traffic areas and Use NT in non-traffic areas.

Bid Set April 2017



2. Provide gray colored sealants unless otherwise indicated on the Drawings, specified, or approved.

PART 3 EXECUTION

3.1 INSTALLATION

A. Waterstops - General

1. Install waterstops for all joints as shown on the Drawings. Provide waterstops continuous around all corners and intersections so that a continuous seal is provided.

2. Provide a minimum number of connections or splices. Replace connections or splices that do not meet the specified requirements at no additional cost to the Owner.

3. Secure waterstops in joints before concrete is placed.

4. Install plastic waterstops so that half of the width will be embedded on each side of the joint. Provide waterstops completely embedded in void-free concrete.

5. Terminate waterstops 2 inches below the exposed top of walls.

6. Protect waterstops from damage in the intervals between placing waterstops and subsequent placing of concrete. Replace damaged or punctured waterstops at no additional cost to the Owner.

7. Provide waterstops free from form release agent, bond breaker, dirt, concrete splatter, ice, mortar, paint, or any other material which could reduce or destroy bond between the waterstop and the concrete to be placed around it.

B. Plastic Waterstops

1. Only straight butt joints are allowed for field splices. Make splices on a bench. Use a power saw and guide to cut straight ends to be spliced. Heat fuse weld splices using a Teflon coated thermostatically controlled waterstop splicing iron following the manufacturer's recommendations. The finished splices shall provide a cross- section that is dense and free of porosity. Engineer may conduct destructive tests of splices by cutting along one half of the splice length and by cutting perpendicular to the splice at several locations on the remaining half of the splice length. The right of the Engineer to make such tests shall not be construed as creating any obligation to make such tests, and not exercising this right to do so shall not relieve the Contractor from meeting the requirements of these Specifications. Completed splices shall exhibit a continuous and uniform bead of excess melted material. The welded material shall not look noticeably different from the parent material. Splices shall not show misalignment of ribs greater than 1/16-in, lack of fusion, porosity, pinholes, cracks, charred or burnt material, bubbles, or separation of cooled splice when bent by hand. If a splice displays any of these defects, reject the splice, recut back at least 1-in from rejected splice on each side, and reweld.

Bid Set April 2017



2. Secure waterstops in wall joints before concrete is placed. If waterstop does not incorporate an integral fastening system, grommets or prepunched holes, drill holes in waterstops between the outermost ribs at each edge. Center the waterstop in the joint. Tie both edges of the waterstop to reinforcing steel with tie wire as specified for tying reinforcing steel. Secure the waterstop centered on and perpendicular to the joint and to maintain this position during concrete placement.

3. Space waterstop ties to match the spacing of the adjacent reinforcing, but ties need not be spaced closer than 12 inches on center.

4. Clamp horizontal waterstops in slabs in position with the form bulkhead (unless previously set in concrete). Lift the edge of the waterstop while placing concrete below the waterstop. Manually force the waterstop against and into the placed concrete and cover with fresh concrete, to provide complete encasement of the waterstop in concrete.

C. Special Waterstops

1. Install special waterstops at joints only where specifically shown on the Drawings. Provide waterstops continuous around all corners and intersections so that a continuous seal is provided.

2. Each piece of the waterstop shall be of maximum practicable length to provide a minimum number of connections or splices. Connections and splices shall conform to the manufacturer's recommendations and as specified herein.

3. Terminate waterstops 2 inches below the exposed top of walls.

4. Splice PVC retrofit waterstops and secure projecting portion to reinforcing steel as specified for plastic waterstops. Clean existing concrete of all foreign material and patch as necessary to form a smooth plane surface. Adhesives, fastening devices, and fastener spacing shall conform to the manufacturer's recommendations.

5. Maximum length of injectable waterstop hose shall be 25 linear feet. Splice consecutive lengths of hose by overlapping in accordance with the manufacturer's specifications. Hold hose in place with anchor clips at the spacing specified by the manufacturer. Do not fasten the injection hoses to reinforcing steel. Patch all visible honeycombs at the concrete surface prior to injection. Begin injection process when concrete has cured not less than 28 days. Perform injection in compliance with manufacturer's specifications and ensure injection hose is properly sealed upon completion.

D. Construction Joints

1. Make construction joints only at locations shown on the Drawings or as approved by the Engineer. Any additional or relocation of construction joints proposed by the Contractor must be submitted to the Engineer for written approval. Do not eliminate construction joints.

Bid Set April 2017



2. Locate additional or relocated joints where they least impair strength of the member. In general, locate joints within the middle third of spans of slabs, beams and girders. However, if a beam intersects a girder at the joint, offset the joint a distance equal to twice the width of the member being connected. Locate joints in walls and columns at the underside of floors, slabs, beams or girders and at tops of footings or floor slabs. Do not locate joints between beams, girders, column capitals, or drop panels and the slabs above them. Do not locate joints between brackets or haunches and walls or columns supporting them.

3. Unless indicated otherwise, provide joints perpendicular to main reinforcement.

Continue reinforcing steel through the joint as indicated on the Drawings.

4. Provide waterstops in wall and slab construction joints in liquid retaining structures and at other locations shown on the Drawings.

5. At all construction joints and at concrete joints indicated on the Drawings to be "roughened", uniformly roughen the surface of the concrete to a minimum Concrete Surface Profile (CSP) 9 per ICRI Guideline 03732 with minimum ¼ inch amplitude (distance between high and low points and side to side). The roughened surface may be accomplished by raking the plastic concrete or by bushhammering or chiseling hardened concrete surfaces. Thoroughly clean joint surfaces of loose or weakened materials by waterblasting or sandblasting and prepare for bonding. At least twelve hours before and again shortly before the new concrete is deposited, saturate the joints and adjacent concrete surfaces to at least 12 inches past the joint with water.

6. Galvanized metal stay-in-place forms shall not be used in the construction joints of any liquid-containing structures.

7. Do not use keyways in construction joints unless specifically shown on the Drawings or approved by the Engineer.

E. Sealant

1. Install sealants in clean dry recesses free of frost, oil, grease, form release agent, loose material, laitance, dirt, dust and other materials which will impair bond at the locations shown on the Drawings. Apply sealant conforming to the manufacturer's recommendations including concrete cure, temperature, moisture, mixing, primer, primer cure time, joint and recess preparation, tooling, and curing. Apply masking tape on the exposed concrete surface of each side of the joint prior to the installation of the sealant and remove afterwards along with any spillage to leave a sealant installation with neat straight edges.

END OF SECTION

Bid Set April 2017




Bid Set April 2017

Cast-In-Place Concrete 03300 - 1


SECTION 03300

CAST-IN-PLACE CONCRETE

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment, and incidentals required and install cast-in- place concrete complete as shown on the Drawings and as specified herein.

B. Furnish, as required to establish concrete mixes, all sampling and laboratory testing of products and materials performed by an independent testing laboratory engaged by and at the expense of the Contractor. Provide field sampling, testing, inspection and related laboratory tests.

1.2 RELATED WORK

A. Watertightness test for water containing structures is included in Section 01480.

B. Plastic lining for cast-in-place concrete is included in Section 02766.

C. Concrete formwork is included in Section 03100.

D. Concrete reinforcement is included in Section 03200.

E. Concrete joints and joint accessories are included in Section 03250.

F. Concrete finishes are included in Section 03350.

G. Grout is included in Section 03600.

H. Modifications to existing concrete are included in Section 03740.

I. Electrical and instrumentation duct encasement concrete is included in Section 03305.

J. Miscellaneous metals are included in Section 05500.

1.3 SUBMITTALS

A. Submit, in accordance with Section PR-9, product data for:

1. Sources of cement, fly ash, aggregates, and batched concrete. Indicate name and address of mill or quarry, as applicable.

2. Air-entraining admixture. Product data including catalogue cut, technical data, storage requirements, product life, recommended dosage, temperature considerations and conformity to ASTM standards.

Bid Set April 2017



3. Water reducing admixture. Product data including catalogue cut, technical data, storage requirements, product life, recommended dosage, temperature considerations and conformity to ASTM standards.

4. Sheet curing material. Product data including catalogue cut, technical data and

conformity to ASTM standard.

5. Material Safety Data Sheets (MSDS) for all concrete components and admixtures.

6. Cold weather and hot weather concreting plans demonstrating how concrete will meet the requirements of this Section including but not limited to concrete mixes, placement, curing and protection.

7. High-range water-reducing admixture (plasticizer). Product data including catalogue cut, technical data, storage requirements, product life, recommended dosage, temperature considerations, retarding effect, slump range and conformity to ASTM standards. Identify proposed locations of use.

8. Liquid membrane forming curing compound. Product data including catalogue cut, technical data, storage requirements, product life, application rate and conformity to ASTM standards. Identify proposed locations of use.

B. Samples

1. Fine and coarse aggregates if requested for examination by the Engineer.

C. Test Reports

1. Aggregates: Conformance to ASTM standards, including sieve analysis, mechanical properties, deleterious substance content, and mortar bar expansion test results.

2. Cement and fly ash: Conformance to ASTM standards, including chemical analysis and physical tests.

3. Concrete mixes: For each formulation of concrete proposed for use, submit constituent quantities per cubic yard, water cementitious ratio, air content, concrete slump, type and manufacturer of cement and type and manufacturer of fly ash. Provide either Paragraph a. or b., below, for each mix proposed.

a. Standard deviation data for each proposed concrete mix based on statistical

records. Provide the following for each strength data point used in the calculation of the standard deviation for determination of the minimum required average strength:

1) Date of sampling and name of testing laboratory. 2) Name of concrete batch plant. 3) Water cementitious ratio. 4) Slump of batch.

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5) Air content of batch. 6) Compressive strengths of all cylinders tested at that age in that batch. 7) If available, temperature and unit weight of batch. 8) Provide data from projects not more strictly controlled than outlined in

these specifications. Provide summary sheet showing all pertinent data and the computation of the standard deviation.

b. Water cementitious ratio curve for concrete mixes based on laboratory tests.

Provide average cylinder strength test results at 7, 14, and 28 days for laboratory concrete mix designs.

D. Certifications

1. Certify that admixtures used in the same concrete mix are compatible with each other and the aggregates.

2. Certify that the Contractor is not associated with the independent testing laboratory proposed for use by the Contractor nor does the Contractor or officers of the Contractor's organization have a beneficial interest in the laboratory.

3. Certificate of conformance for concrete production facilities from the NRMCA.

E. Qualifications

1. Independent Testing Laboratory

a. Name and address

b. Names and positions of principal officers and the name, position, and qualifications of the responsible registered professional engineer in charge.

c. Listing of technical services to be provided. Indicate external technical

services to be provided by other organizations.

d. Names and qualifications of the supervising laboratory technicians.

e. Statement of conformance provided by evaluation authority defined in ASTM C1077. Provide report prepared by evaluation authority when requested by the Engineer.

f. Submit as required above for other organizations that will provide external

technical services.



1. ASTM C31 - Standard Practice for Making and Curing Concrete Test Specimens in the Field.

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2. ASTM C33 - Standard Specification for Concrete Aggregates.

3. ASTM C39 - Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens.

4. ASTM C42 - Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete.

5. ASTM C94 - Standard Specification for Ready-Mixed Concrete.

6. ASTM C138 - Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete.

7. ASTM C143 - Standard Test Method for Slump of Hydraulic-Cement Concrete

8. ASTM C150 - Standard Specification for Portland Cement

9. ASTM C156 - Standard Test Method for Water Retention by Liquid Membrane- Forming Curing Compound for Concrete

10. ASTM C171 - Standard Specification for Sheet Materials for Curing Concrete

11. ASTM C173 - Standard Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method.

12. ASTM C192 - Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory.

13. ASTM C231 - Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method.

14. ASTM C260 - Standard Specification for Air-Entraining Admixtures for Concrete.

15. ASTM C309 - Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete.

16. ASTM C311 - Standard Test Methods for Sampling and Testing Fly Ash or Natural Pozzolans for use in Portland Cement Concrete.

17. ASTM C494 - Standard Specification for Chemical Admixtures for Concrete.

18. ASTM C618 - Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete.

19. ASTM C1017 - Standard Specification for Chemical Admixtures for use in Producing Flowing Concrete.

20. ASTM C1077 - Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation.

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21. ASTM C1260 - Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method).

22. ASTM E329 - Standard Specification for Agencies Engaged in Construction Inspection and/or Testing.

B. American Concrete Institute (ACI).

1. ACI 211.1 - Standard Practice for Selecting Proportions for Normal, Heavyweight and Mass Concrete.

2. ACI 232.2R - Use of Fly Ash in Concrete.

3. ACI 304R - Guide for Measuring, Mixing, Transporting and Placing Concrete.

4. ACI 304.2R - Placing Concrete by Pumping Methods.

5. ACI 305R - Hot Weather Concreting.

6. ACI 306R - Cold Weather Concreting.

7. ACI 318 – Building Code Requirements for Structural Concrete.

8. ACI 350 - Code Requirements for Environmental Engineering Concrete Structures and Commentary.

C. National Ready Mixed Concrete Association (NRMCA)

1. Quality Control Manual, Section 3 - Certification of Ready Mixed Concrete Production Facilities.

D. Truck Mixer Manufacturers Bureau (TMMB)

1. TMMB 100 - Truck Mixer, Agitator and Front Discharge Concrete Carrier Standards.



A. Comply with ACI 318, ACI 350 and other stated specifications, codes and standards. Apply the most stringent requirements of other stated specifications, codes, standards, and this Section when conflicts exist.

B. Independent testing laboratory shall meet the requirements of ASTM E329 and ASTM C1077 and be acceptable to the Engineer. Laboratories affiliated with the Contractor or in which the Contractor or officers of the Contractor's organization have a beneficial interest are not acceptable.

Bid Set April 2017



C. Use only one source of cement and aggregates for the project. Provide concrete uniform in color and appearance.

D. At least ten working days before the first concrete placement hold a preconstruction meeting to review the requirements for concrete placement, waterstop placement, jointing, concrete curing, hot weather concreting, cold weather concreting and finishing. Review, with the attendance of the plasticizer manufacturer, the properties and techniques of batching and placing concrete containing high-range water-reducing admixture. Notify all parties involved, including the Engineer, of the meeting at least ten working days prior to its scheduled date. Prepare an agenda for the meeting. Take meeting minutes and distribute to all attendees.

E. If, during the progress of the work, it is impossible to secure concrete of the specified workability and strength with the materials being furnished, the Engineer may order such changes in proportions or materials, or both, as may be necessary to secure the specified properties. Make all changes so ordered at no additional cost to the Owner.

F. If, during the progress of the work, the materials from the sources originally accepted change in characteristics, make, at no additional cost to the Owner, new acceptance tests of materials and establish new concrete mixes with the assistance of an independent testing laboratory.

G. Provide all field testing and inspection services and related laboratory tests. Methods of testing shall comply with the latest applicable ASTM methods. The following items shall be tested to verify conformity with this Section.

1. Concrete placements - compressive strength (cylinders), compressive strength (cores), temperature, slump, and air content.

2. Shrinkage.

3. Other materials that may require field testing.

H. Shrinkage Tests: The Contractor’s independent testing firm shall perform shrinkage tests on the design mix for Class D concrete. All specimens shall be cast in the laboratory. Concrete and not mortar specimens shall be used. The tests shall conform to ASTM C157 modified as follows:

1. Three 4- by 4- by 11-inch test specimens, with 10 inches gage length shall be made.

2. Specimens shall be removed from molds at an age of 23+1 hours after trial batching, and placed immediately in water at 73oF+3o for at least 30 minutes.

3. Specimens shall be measured 30 minutes thereafter to determine the original

length, and then submerged in saturated lime water at 73oF+3o.

4. Measurement to determine expansion expressed as a percentage of original length shall be made at age 7 days. The length at 7 days shall be made the base length for drying shrinkage calculations.

Bid Set April 2017



5. Specimens shall be stored in a humidity control room maintained at 73oF+3o and 50%+4% relative humidity for the remainder of the test.

6. Measurements to determine shrinkage expressed as a percentage of base length shall be made and reported separately for 7, 14, and 21 days of drying after 7 days of moist curing.

7. The average shrinkage at 21 days of air storage shall not exceed 0.040 percent.

I. Provide laboratory tests of samples of constituents and of concrete as-placed. All materials incorporated in the work shall conform to accepted samples.


A. Cement: Store in weathertight buildings, bins or silos to provide protection from dampness and contamination and to prevent warehouse set.

B. Aggregate: Arrange and use stockpiles to prevent segregation or contamination with other materials or with other sizes of like aggregates. Build stockpiles in successive horizontal layers not exceeding three feet in thickness. Complete each layer before the next is started. Do not use frozen or partially frozen aggregate.

C. Sand: Arrange and use stockpiles to prevent contamination. Allow sand to drain to a uniform moisture content before using. Do not use frozen or partially frozen sand.

D. Admixtures: Store in closed containers to prevent contamination, evaporation or damage. Provide agitating equipment to uniformly disperse ingredients in admixture solutions which tend to separate. Protect liquid admixtures from freezing and other temperature changes which could adversely affect their characteristics.

E. Fly Ash: Store in weathertight buildings, bins or silos to provide protection from dampness and contamination.

F. Sheet Curing Materials: Store in weathertight buildings or off the ground and under cover.

G. Liquid Membrane Forming Curing Compounds: Store in closed containers.

PART 2 PRODUCTS 2.1 GENERAL

A. The use of manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired.

B. Like items of materials shall be the end products of one manufacturer in order to

provide standardization for appearance, maintenance and manufacturer's service.

2.2 MATERIALS

A. Materials shall comply with this Section and any applicable State or local requirements.

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B. Cement: Domestic portland cement conforming to ASTM C150. Cement shall be low alkali cement. Do not use air entraining cements. Cement brand must be approved by the Engineer and one brand shall be used throughout the work. Provide the following type(s) of cement:

1. Class A Concrete - Type II with the equivalent alkalies, as defined in table 2 of ASTM C150, limited to a maximum of 0.6 percent (low-alkali cement).

2. Class D Concrete - Type II, low-alkali cement with fly ash resulting in C3A being

below 8 percent of total cementitious content.

C. Aggregates:

1. Fine Aggregate: Washed inert natural sand conforming to ASTM C33.

2. Coarse Aggregate: Well-graded crushed stone or washed gravel conforming to ASTM C33. Grading requirements as listed in ASTM C33, Table 3 for the specified coarse aggregate size number listed in Table 1 herein. Limits of deleterious substances and physical property requirements as listed in ASTM C33, Table 4 for severe weathering regions. Do not use coarse aggregates known to be deleteriously reactive with alkalis in cement.

3. The fine and coarse aggregates used shall not cause expansion of mortar bars greater than 0.1 percent in 16 days when tested in accordance with ASTM C1260 and using the cement proposed for the project. If aggregates proposed for use do not meet this requirement, then satisfy either a. or b. below.

a. Total equivalent alkali content of the cement used shall not exceed 0.60

percent as provided in the Optional Chemical Requirements of ASTM C150.

b. The fine and coarse aggregates used shall not cause expansion of mortar bars greater than 0.1 percent in 16 days when tested in accordance with ASTM C1260 and using the cement and fly ash proposed for the project. The proportions of the cement-fly ash mix shall be the same as those proposed for the project.

D. Water: Potable water free of oil, acid, alkali, salts, chlorides (except those attributable to drinking water), organic matter, or other deleterious substances.

E. Admixtures: Use admixtures free of chlorides and alkalis (except for those attributable to drinking water). The admixtures shall be from the same manufacturer when it is required to use more than one admixture in the same concrete mix. Use admixtures compatible with the concrete mix including other admixtures.

1. Air Entraining Admixture: Conforming to ASTM C260. Proportion and mix in accordance with manufacturer's recommendations.

2. Water Reducing Admixture: Conforming to ASTM C494, Type A. Proportion and mix in accordance with manufacturer's recommendations.

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3. High-Range Water-Reducing Admixtures (Plasticizer): Conforming to ASTM C494, Type F or ASTM C1017, Type I resulting in non-segregating plasticized concrete with little bleeding and with the physical properties of low water/cementitious ratio concrete. The treated concrete shall be capable of maintaining its plastic state in excess of 2 hours. Proportion and mix in accordance with manufacturer's recommendations.

4. Do not use admixtures causing retarded or accelerated setting of concrete without written approval from the Engineer. Use retarding or accelerating water reducing admixtures when so approved.

F. Supplementary Cementitious Materials

1. Fly Ash: Class F fly ash complying with ASTM C618, including the requirements of Table 1 but with the Loss on Ignition (LOI) limited to 3 percent maximum and the optional physical requirements of Table 3. Test in compliance with ASTM C311 with a minimum of one sample weighing four pounds taken from each 200 tons of fly ash supplied for the project.

G. Sheet Curing Materials: Waterproof paper, polyethylene film or white burlap- polyethylene sheeting, all conforming to ASTM C171.

H. Liquid Membrane-Forming Curing Compound. Compound conforming to ASTM C309, Type 1-D (clear or translucent with fugitive dye) and containing no wax, paraffin, or oil. Curing compounds shall be non-yellowing and have a unit moisture loss no greater than 0.039 gm/cm2 at 72 hours as measured by ASTM C156. Curing compound shall comply with Federal, State and local VOC limits.

2.3 MIXES

A. An independent testing laboratory engaged by and at the expense of the Contractor shall establish concrete mixes and perform all sampling and laboratory testing of products and materials.

B. Select proportions of ingredients to meet the design strength and materials limits specified in Table 1 and to produce placeable, durable concrete conforming to these specifications. Proportion ingredients to produce a homogenous mixture which will readily work into corners and angles of forms and around reinforcement without permitting materials to segregate or allowing free water to collect on the surface.

C. Base concrete mixes on standard deviation data of prior mixes with essentially the same proportions of the same constituents or, if not available, develop concrete mixes by laboratory tests using the materials proposed for the work.

1. For concrete mixes based on standard deviation data of prior mixes, submit standard deviation data of prior mixes with essentially the same proportions of the same constituents in accordance with ACI 318 and based on the modification factors for standard deviation tests contained in ACI 318.

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2. For concrete mixes developed by laboratory testing, base cementitious content of the concrete on curves showing the relation between water cementitious ratio and 7, 14 and 28-day compressive strengths of concrete made using the proposed materials. Determine curves by four or more points, each representing an average value of at least three test specimens and one water-cementitious ratio at each age. Provide curves with a range of values sufficient to yield the desired data, including the compressive strengths specified, without extrapolation. The cementitious content of the concrete mixes to be used, as determined from the curve, shall correspond to the required average compressive strength in Table 5.3.2.2 of ACI 318. The resulting mix shall not conflict with the limiting values for maximum water cementitious ratio and net minimum cementitious content specified in Table 1.

D. Test the fly ash and concrete mixture to provide test data confirming that the fly ash in combination with the cement to be used meets all strength requirements and is compatible with the other concrete additives.

E. Test aggregates for potential alkali reactivity in accordance with ASTM C1260. If initial

testing indicates aggregates are not potentially reactive repeat test at 3-month intervals.

F. Compression Tests: Provide testing of the proposed concrete mixes to demonstrate compliance with the compression strength requirements in conformity with the provisions of ACI 318.

G. Total air content, as measured by ASTM C231, shall be as shown in Table 1 and shall be achieved through an appropriate doseage of air entraining admixture.

1. If the air entraining agent proposed for use in the mix requires testing methods other than ASTM C231 to accurately determine air content, make special note of this requirement in the admixture submittal specified under Paragraph 1.03.

H. Slump of the concrete as measured by ASTM C143, shall be as shown in Table 1. If a high-range water-reducing admixture (plasticizer) is used, the slump indicated shall be that measured before plasticizer is added. Plasticized concrete shall have a slump ranging from 7 to 10-in.

I. Proportion admixtures according to the manufacturer's recommendations. Two or more admixtures specified may be used in the same mix provided that the admixtures in combination retain full efficiency and have no deleterious effect on the concrete or on the properties of the other admixture(s).

TABLE 1

Design Fine Coarse Cementitious Class Strength Cement Aggregate Aggregate Content

1 2 3 3 4 A 2500 Type II Sand 57 440 D 4500 Type II Sand 57 560

W/C Air content

Slump

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TABLE 1 (continued)

Class Ratio SCM Range WR HRW R

Range

5 6 7 8 9 Inches A 0.62 max. Yes 3.5 to 5 Yes No 1-4 D 0.42 max. Yes 3.5 to 5 Yes No 3-5

TABLE NOTES:

1. Minimum compressive strength in psi at 28 days

2. ASTM designation in ASTM C150

3. Size Number in ASTM C33

4. Minimum cementitious content in lbs per cubic yard (where fly ash is used cementitious content is defined as cement content plus fly ash content)

5. W/C is Maximum Water Cementitious ratio by weight

6. Supplementary Cementitious Material (SCM) fly ash content in the range of 20-25 percent of the total cement content plus fly ash content, by weight

7. Total air content consists of entrapped air and entrained air as measured in accordance with ASTM C231

8. WR is water reducing admixture

9. HRWR is high-range water-reducing admixture

PART 3 EXECUTION

3.1 MEASURING MATERIALS

A. Provide concrete composed of portland cement, fly ash, fine aggregate, coarse aggregate, water and admixtures as specified and produced by a plant complying with ACI 318 and ASTM C94. Batch all constituents, including admixtures, at the plant. High-range water reducing admixtures may be added in the field.

B. Measure materials for batching concrete by weighing in conformity with and within the tolerances given in ASTM C94 except as otherwise specified. Use scales last certified by the local Sealer of Weights and Measures within one year of use.

C. Weigh cement and fly ash in individual weigh batchers that are separate and distinct from the weigh batchers used for other materials. When cement and fly ash are weighed in a cumulative weigh batcher, the cement shall be weighed first.

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D. Measure the amount of free water in fine aggregates within 0.5 percent with a moisture meter. Compensate for varying moisture contents of fine aggregates. Record the number of gallons of water as-batched on printed batch tickets.

E. Dispense admixtures either manually using calibrated containers or measuring tanks, or

by means of an automatic dispenser approved by the manufacturer of the specific admixture.

1. Charge air-entraining and chemical admixtures into the mixer as a solution using an automatic dispenser or similar metering device.

2. Inject multiple admixtures separately during the batching sequence.

3.2 MIXING AND TRANSPORTING

A. Provide ready-mixed concrete produced by equipment complying with ACI 318 and ASTM C94 and produced by a plant certified by the NRMCA. Do not hand-mix. All truck mixers shall carry a rating plate conforming to TMMB 100. Clean each transit mix truck drum and reverse drum rotation before the truck proceeds under the batching plant. Equip each transit-mix truck with a continuous, nonreversible, revolution counter showing the number of revolutions at mixing speeds.

B. Transport ready-mix concrete to the site in watertight agitator or mixer trucks loaded not in excess of their rated capacities as stated on the name plate.

C. Keep the water tank valve on each transit truck locked at all times. Any addition of water must be directed by the Engineer. Incorporate water directed to be added by additional mixing of at least 50 revolutions at mixing speed after the addition of all water. Meter all added water and show the amount of water added on each delivery ticket.

D. Comply with ACI 318 and ASTM C94 for all central plant and rolling stock equipment and methods.

E. Select equipment of size and design to provide continuous flow of concrete at the delivery end. Use metal or metal-lined non-aluminum discharge chutes with slopes not exceeding one vertical to two horizontal and not less than one vertical to three horizontal. Chutes more than 20-ft long and chutes not meeting slope requirements may be used if concrete is discharged into a hopper before distribution.

F. Do not retemper (mix with or without additional cement, aggregate, or water) concrete or mortar which has partially hardened.

G. Handle concrete from mixer to placement providing concrete of specified quality in the placement area and not exceeding the maximum time interval specified in Paragraph 3.02 I.4. Dispatch trucks from the batching plant so they arrive at the work site just before the concrete is required to avoid excessive mixing of concrete while waiting or delays in placing successive layers of concrete in the forms. Remix for a minimum of 5 minutes prior to discharge or testing.

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H. Furnish a delivery ticket for ready mixed concrete to the Engineer as each truck arrives. Provide a printed record of the weight of cement and each aggregate as batched individually on each ticket. Use the type of indicator that returns for zero punch or returns to zero after a batch is discharged. Indicate for each batch the weight of fine and coarse aggregate, cement, fly ash, and water, moisture content of fine and coarse aggregate at time of batching, and types, brand and quantity of each admixture, the quantity of concrete delivered, the time any water is added and the amount, and the numerical sequence of the delivery. Show the time of day batched and time of discharge from the truck. Indicate the number of revolutions of transit mix truck.

I. Temperature and Mixing Time Control

1. In cold weather (see Paragraph 3.07D) maintain the as-mixed temperature of the concrete and concrete temperatures at the time of placement in the forms as indicated in Table 3.

2. If water or aggregate has been heated, combine water with aggregate in the mixer before cement is added. Do not add cement to mixtures of water and aggregate when the temperature of the mixture is greater than 90 degrees F.

3. In hot weather (see Paragraph 3.07E), cool ingredients before mixing to maintain temperature of the concrete below the maximum placing temperature of 90 degrees F. Well-crushed ice may be substituted for all or part of the mixing water.

4. The maximum time interval between the addition of mixing water and/or cement to the batch and the final placing of concrete in the forms shall not exceed the values shown in the following Table 2:

TABLE 2

AIR OR CONCRETE TEMPERATURE (WHICHEVER IS HIGHER)

MAXIMUM TIME

(27 Degree C) 80 Degree F to 90 Degree F (32 Degree C) 45 minutes (21 Degree C) 70 Degree F to 79 Degree F (26 Degree C) 60 minutes (5 Degree C) 40 Degree F to 69 Degree F (20 Degree C) 90 minutes

5. If an approved high-range water-reducing admixture (plasticizer) is used to produce plasticized concrete, the maximum time interval between the addition of mixing water and/or cement to the batch and the final placing of concrete in the forms shall not exceed 90 minutes.

3.3 INSPECTION AND COORDINATION

A. Batching, mixing, transporting, placing and curing of concrete shall be subject to the inspection of the Engineer at all times. Advise the Engineer of readiness to proceed at least six working hours prior to each concrete placement. The Registered Deputy Inspector will inspect the preparations for concreting including the preparation of previously placed concrete, the reinforcing and the alignment, cleanliness and tightness of formwork. Do not place concrete without the inspection and acceptance of the Registered Deputy Inspector.

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3.4 EMBEDDED ITEMS

A. Secure to forms as required or set for embedment as required, all miscellaneous metal items, sleeves, reglets, anchor bolts, anchors, inserts and other items furnished under other Sections and required to be embedded into concrete. Set and secure such items in the locations and alignments needed so they are not displaced by concrete placement.

B. Clean embedded items free of rust, mud, dirt, grease, oil, ice, or other contaminants which would reduce or prevent bonding with concrete.

C. Coat or isolate all aluminum embedments to prevent aluminum-concrete reaction or electrolytic action between aluminum and steel.

D. Do not embed piping in concrete unless shown on the Drawings.

E. Do not embed electrical conduits in concrete unless shown on the Drawings.

F. Fabricate piping and conduit such that the cutting, bending, or relocation of reinforcing steel is not required. Pipes and conduits embedded within a slab or wall (other than those merely passing through) shall satisfy the following, unless otherwise shown on the Drawings or approved:

1. Maximum outside dimension of pipe or conduit shall not be greater than one third the overall thickness of the slab or wall.

2. Spacing of pipes or conduits shall be greater than or equal to three diameters or widths on center.

G. Close open ends of piping, conduits, and sleeves embedded in concrete with caps or plugs prior to placing concrete.

H. Ensure all specified tests and inspections on embedded piping are completed and satisfactory before starting concrete placement. Ensure all mechanical or electrical tests and inspections are completed and satisfactory prior to starting concrete placement. Do not place concrete until unsatisfactory items and conditions have been corrected.

I. Position embedded anchor bolts using templates.

J. Check location, alignment, and support of anchor bolts, piping, electrical conduits, and other items which will be fully or partially embedded in concrete before depositing concrete. Correct mislocated and misaligned items and secure items which have become loose before depositing concrete.

K. Correct all embedded items not installed in the location or alignment needed or displaced by concrete placement at no additional cost to the Owner.

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3.5 CONCRETE APPEARANCE

A. Remix concrete showing either poor cohesion or poor coating of the coarse aggregate with paste. Reject remixed concrete showing either poor cohesion or poor coating of the coarse aggregate with paste. Make, at no additional cost to the Owner, changes in the concrete mix design for future deliveries only by adjusting one or more of the following if the slump is within the allowable limit, but excessive bleeding, poor workability, or poor finishability are observed:

1. The gradation of aggregate.

2. The proportion of fine and coarse aggregate.

3. The percentage of entrained air, within the allowable limits.

B. Provide concrete having a homogeneous structure which, when hardened, will have the specified strength, durability and appearance. Provide mixtures and workmanship such that concrete surfaces, when exposed, will require no finishing except as specified in Section 03350.

3.6 PLACING AND COMPACTING

A. Placing

1. Verify that all formwork completely encloses concrete to be placed and is securely braced prior to concrete placement. Remove ice, standing water, dirt, debris, and other foreign materials from forms and exposed joint surfaces. Confirm that reinforcement and other embedded items are securely in place. Have a worker at the location of the placement who can check that reinforcement and embedded items remain in designated locations and alignments while concrete is being placed. Sprinkle semi-porous subgrades or forms to eliminate suction of water from the mix. Do not place concrete on frozen subgrade, snow, or ice.

2. Deposit concrete as near its final position as possible to prevent segregation due to rehandling or flowing. Place concrete continuously at a rate that allows the concrete previously placed to be integrated with fresh plastic concrete. Do not deposit concrete which has partially hardened or has been contaminated by foreign materials or on concrete which has hardened sufficiently to cause formation of seams or planes of weakness within the section. If the section cannot be placed continuously, place construction joints as specified or as approved.

3. Pumping of concrete will be permitted. Use a mix design and aggregate sizes chosen for pumping and submit for approval. Do not use pipelines made of aluminum or aluminum alloy. When concrete is pumped, slump will be determined at point of truck discharge and air content will be determined at point of placement.

4. Remove temporary spreaders from forms when the spreader is no longer needed. Temporary spreaders may remain embedded in concrete only when made of galvanized steel or concrete and if prior approval has been obtained.

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5. Do not place concrete for supported elements until concrete previously placed in the supporting element has attained design strength.

6. Where surface mortar is to form the base of a finish, especially surfaces designated to be painted, work coarse aggregate back from forms to bring the full surface of the mortar against the form. Prevent the formation of surface voids.

7. Slabs

a. After bulkheads, screeds and jointing materials have been positioned, place concrete continuously between joints beginning at a bulkhead, edgeform, or corner. Place each batch into the edge of the previously placed concrete to avoid stone pockets and segregation.

b. Avoid delays in placement. If there is a delay in placement, spade and consolidate the concrete placed after the delay at the edge of the previously placed concrete to avoid cold joints. Bring concrete to correct level and strike off with a straightedge. Use bullfloats or darbies to smooth the surface, leaving it free of humps or hollows.

c. Where slabs are to be placed integrally with the walls below them, place the walls and compact as specified. Allow one hour to pass between placement of the wall and the overlying slab to permit consolidation of the wall concrete. Keep the top surface of the wall moist to prevent cold joints.

8. Formed Concrete a. Place concrete in forms using tremie tubes taking care to prevent segregation.

Maintain bottom of tremie tubes in contact with the concrete already placed. Do not permit concrete to drop freely more than 4-feet. Place concrete for walls in 12-inches to 24-inches lifts, keeping the surface horizontal. If a high- range water-reducing admixture is used do not permit concrete to drop freely more than 15-ft; maximum lift thickness not to exceed 7-ft.

B. Compacting

1. Consolidate concrete by vibration and puddling, spading, rodding or forking so that concrete is completely worked around reinforcement, embedded items and openings and into corners of forms. Continuously perform puddling, spading, rodding and forking along with vibration of the placement to eliminate air or stone pockets which may cause honeycombing, pitting or planes of weakness.

2. Compact all concrete with mechanical vibrators. Do not order concrete until vibrators (including standby units in working order) are on the job.

3. Use mechanical vibrators having a minimum frequency of 8000 vibrations per minute. Insert vibrators and withdraw at points from 18- to 30-inches apart. Vibrate sufficiently at each insertion to consolidate concrete, generally from 5 to 15 seconds. Do not over vibrate so as to segregate. Keep standby vibrators on the site during concrete placing operations.

4. Concrete Slabs: Vibration for concrete slabs less than 8-in thick shall be by vibrating screeds. Vibration for concrete slabs 8-in and thicker shall be by internal

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vibrators and (optionally) with vibrating screeds. Place vibrators into concrete vertically. Do not lay vibrators horizontally or lay over.

5. Walls and Columns: Use internal vibrators (rather than form vibrators) unless otherwise approved by the Engineer. In general, for each vibrator needed to melt down (level) the batch at the point of discharge, one or more additional vibrators must be used to densify, homogenize and perfect the surface. Insert vibrators vertically at regular intervals, through the fresh concrete and slightly into the previous lift, if any.

6. Amount of Vibration: Use vibrators to consolidate properly placed concrete. Do not use vibrators to move or transport concrete in the forms. Continue vibration until: a. Frequency of vibrator returns to normal. b. Surface appears liquefied, flattened and glistening. c. Trapped air ceases to rise. d. Coarse aggregate has blended into surface, but has not disappeared.

3.7 CURING AND PROTECTION

A. Protect all concrete work against injury from the elements and defacements of any nature during construction operations.

B. Curing Methods

1. Curing Methods for Concrete Surfaces: Cure concrete to retain moisture and maintain a temperature of at least 50 Degrees F at the concrete surface for a minimum of seven days after placement. Use the following curing methods as specified:

a. Water Curing: Keep entire concrete surface wet by ponding, continuous

sprinkling or covered with saturated burlap. Begin water curing as soon as concrete attains an initial set and maintain water curing 24 hours a day. Do not permit the surface of the concrete to dry out at any time during the curing period. Temperature of curing water shall be within 20 Degrees F of the concrete temperature.

b. Sheet Material Curing: Cover entire surface with sheet material. Anchor sheeting to prevent wind and air from lifting the sheeting or entrapping air under the sheet. Place and secure sheet as soon as initial concrete set occurs.

c. Liquid Membrane Curing: Apply over the entire concrete surface except as

follows. Curing compound shall NOT be placed on any concrete surface where additional concrete or grout is to be placed, where concrete sealers or surface coatings are to be used, or where the concrete finish requires an integral floor product. Apply curing compound as soon as the free water on the surface has disappeared and no water sheen is visible, but not after the concrete is dry or when the curing compound can be absorbed into the concrete. Apply in compliance with the manufacturer's recommendations.

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2. Specified applications of curing methods:

a. Slabs for Liquid Retaining Structures: Water curing only.

b. Slabs on Grade and Footings (not used to retain liquids): Water curing or sheet material curing or liquid membrane curing.

c. Structural Slabs (other than Liquid Retaining Structures): Water curing or

liquid membrane curing.

d. Horizontal Surfaces which will Receive Additional Concrete, Coatings, Grout or Other Material that Requires Bond to the substrate: Water curing.

e. Formed Surfaces: None if nonabsorbent forms are left in place seven days.

Water curing if absorbent forms are used. Water curing if forms are removed prior to seven days. Exposed horizontal surfaces of formed walls or columns shall be water cured for seven days or until next placement of concrete is made.

f. Surfaces of Concrete Joints: Water curing or sheet material curing.

C. Protect finished surfaces and slabs from the direct rays of the sun to prevent checking and crazing.

D. Cold Weather Concreting

1. For this Specification, "cold weather" is defined as a period when for more than three successive days, the average daily outdoor temperature drops below 40 degrees F. Calculate average daily temperature as the average of the highest and the lowest temperature during the period from midnight to midnight.

2. Batch, deliver, place, cure and protect concrete during cold weather in compliance with the recommendations of ACI 306R and the additional requirements of this Section.

3. Review the cold weather concreting plan at the preconstruction meeting. Include the methods and procedures for use during cold weather including the production, transportation, placement, protection, curing and temperature monitoring of the concrete and the procedures to be implemented upon abrupt changes in weather conditions or equipment failures.

4. The minimum temperature of concrete immediately after placement and during the protection period shall be as indicated in Table 3. The temperature of the concrete in place and during the protection period shall not exceed these values by more than 20 degrees F. Prevent overheating and non-uniform heating of the concrete.

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TABLE 3

Concrete Temperatures Minimum Dimension of Section

< 12-in 12 to 36-in

Min. conc temp: 55 Degree F 50 Degree F

5. Protect concrete during periods of cold weather to provide continuous warm, moist curing (with supplementary heat when required by weather conditions) for a total of at least 350 degree-days of curing.

a. Degree-days are defined as the total number of 24 hour periods multiplied by

the weighted average daily air temperature at the surface of the concrete (e.g., 7 days at an average 50 degrees F = 350 degree-days).

b. To calculate the weighted average daily air temperature, sum hourly

measurements of the air temperature in the shade at the surface of the concrete taking any measurement less than 50 degrees F as 0 degrees F. Divide the sum thus calculated by 24 to obtain the weighted average temperature for that day.

6. Do not use salt, manure or other chemicals for protection.

7. At the end of the protection period, allow the concrete to cool gradually to the ambient temperature. If water curing has been used, do not expose concrete to temperatures below those shown in Table 3 until at least 24 hours after water curing has been terminated and air dry concrete for at least 3 days prior to first exposure to freezing temperatures.

8. During periods not defined as cold weather, but when freezing temperatures are expected or occur, protect concrete surfaces from freezing for the first 24 hours after placing.

E. Hot Weather Concreting

1. For this Specification, "hot weather" is defined as any combination of high air temperatures, low relative humidity and wind velocity which produces a rate of evaporation as estimated in ACI 305R, approaching or exceeding 0.2 pounds per square foot per hour (lb/sq ft/hr).

2. Batch, deliver, place, cure and protect concrete during hot weather in compliance with the recommendations of ACI 305R and the additional requirements of this Section.

a. Temperature of concrete being placed shall not exceed 90 degrees F.

Maintain a uniform concrete mix temperature below this level. The temperature of the concrete shall not cause loss of slump, flash set or cold joints.

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b. Promptly deliver concrete to the site and promptly place the concrete upon its arrival at the site, not exceeding the maximum time interval specified in Paragraph 3.02I.4. Provide vibration immediately after placement.

c. The Engineer may direct the Contractor to immediately cover concrete with

sheet curing material.

3. Review the hot weather concreting plan at the preconstruction meeting. Include the methods and procedures for use during hot weather including production, placement, and curing.

3.8 REMOVAL OF FORMS

A. Do not remove forms before the concrete has attained a strength of at least 70 percent of its specified design strength for beams and slabs and at least 30 percent of its specified design strength for walls and vertical surfaces, nor before reaching the following number of day-degrees of curing (whichever is the longer):

TABLE 4

Forms for Degree Days

Beams and slabs 500 Walls and vertical surfaces 100

(See definition of degree-days in Paragraph 3.07D).

B. Do not remove shores until the concrete has attained at least 70 percent of its specified design strength and also sufficient strength to support safely its own weight and the construction live loads upon it.

C. In cold weather, when temperature of concrete exceeds ambient air temperature by 20 Degrees F at the end of the protection period, loosen forms and leave in place for at least 24 hours to allow concrete to cool gradually to ambient air temperature.

3.9 FIELD AND LABORATORY TESTS

A. Take field control cylinder specimens during the progress of the work, in compliance with ASTM C31. The number of sets of concrete test cylinders taken of each class of concrete placed each day shall not be less than one set per day, nor less than one set for each 100 cu yds of concrete nor less than one set for each 5,000 sq ft of surface area for slabs or walls. Specimens shall be formed in 6-in diameter by 12-in long nonabsorbent cylindrical molds.

1. A "set" of test cylinders shall consist of six cylinders: one to be tested at three days, one to be tested at seven days, one to be tested at 14 days, and two to be tested and their strengths averaged at 28 days. The sixth may be used to verify strength after 28 days if 28 day test results are low.

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2. When the average 28 day compressive strength of the cylinders in any set falls below the required compressive strength or below proportional minimum 7- or 14- day strengths (where proper relation between 7-, 14 and 28 day strengths have been established by tests), change proportions, cementitious content, or temperature conditions to achieve the required strengths at no additional cost to the Owner.

B. Provide four firmly braced, insulated, heated, closed wooden curing boxes, each sized to hold ten specimens, complete with cold weather temperature and hot weather temperature control thermostat for initial curing and storage from time of fabrication until shipment to the testing lab. Protect the specimens against injury or loss through construction operations.

C. Test slump immediately prior to placing the concrete. Test shall be made in accordance with ASTM C143. When concrete is pumped, slump will be determined at point of truck discharge. If the slump is outside the specified range, the concrete will be rejected.

D. Test for air content shall be conducted on a fresh concrete sample. Air content for

concrete made of ordinary aggregates having low absorption shall be made in compliance with either the pressure method complying with ASTM C231 or by the volumetric method complying with ASTM C173. If aggregates with high absorptions are used, the latter test method shall be used. When concrete is pumped, air content will be determined at point of placement.

E. Shrinkage

1. Field test specimens shall be handled and and tested by the Contractor’s independent testing firm as specified in Paragraph 1.05H. A set of test cylinders shall be taken from the first batch of concrete and any initial batch thereafter in which the source of concrete ingredients has changed.

2. The maximum concrete shrinkage for specimens cast in the field shall not exceed the trial batch maximum shrinkage requirement by more than 25 percent.

3. If the required shrinkage limitation is not met during construction, the Contractor shall take any or all of the following actions, at no additional cost to the Owner, to achieve the specified shrinkage requirements. These actions may include changing the source of the aggregates, cement and/or admixtures; reducing water content; washing of aggregate to reduce fines; increasing the number of construction joints; modifying the curing requirements; or other actions designed to minimize shrinkage or the effects of shrinkage.

3.10 FIELD CONTROL

A. The Engineer may have cores taken from any questionable area in the concrete work such as construction joints and other locations as required for determination of concrete quality. The results of tests on such cores shall be the basis for acceptance, rejection or determining the continuation of concrete work. The right of the Engineer to take such cores shall not be construed as creating any obligation to take such cores,

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and not exercising this right to do so shall not relieve the Contractor from meeting the requirements of these Specifications.

B. Cooperate in obtaining cores by allowing free access to the work and permitting the use of ladders, scaffolding and such incidental equipment as may be required. Repair all core holes with non-shrink grout as specified in Section 03600. The work of cutting, testing and repairing the cores will be at the expense of the Contractor if defective work is uncovered. If no defective work is found, such cost will be at the expense of the Owner.

3.11 FAILURE TO MEET REQUIREMENTS

A. Should the strengths shown by the test specimens made and tested in compliance with the previous provisions fall below the values given in Table 1, the Engineer may require changes in proportions or materials, or both, to apply to the remainder of the work in accordance with Paragraph 1.05E. Furthermore, the Engineer may require additional curing on those portions of the structure represented by the test specimens which fall below the values given in Table 1. The cost of such additional curing shall be at no additional cost to the Owner. In the event that such additional curing does not give the strength required, as evidenced by core and/or load tests, the Engineer may require strengthening or replacement of those portions of the structure which fail to develop the required strength. Coring and testing and/or load tests and any strengthening or concrete replacement required because strengths of test specimens are below that specified, shall be at no additional cost to the Owner. In such cases of failure to meet strength requirements, the Contractor and Owner shall confer to determine what adjustment, if any, can be made in compliance with Sections titled "Strength" and "Failure to Meet Strength Requirements" of ASTM C94. The "purchaser" referred to in C94 is the Contractor.

B. When the tests on control specimens of concrete fall below the required strength, the Engineer will permit check tests for strengths to be made by means of typical cores drilled from the structure in compliance with ASTM C42 and C39. In cases where tests of cores fall below the values given in Table 1, the Engineer, in addition to other recourses, may require load tests on any one of the slabs, walls, beams, and columns in which such concrete was used. Test need not be made until concrete has aged 60 days. The Engineer may require strengthening or replacement of those portions of the structure which fail to develop the required strength. All coring and testing and/or load tests and any strengthening or concrete replacement required because strengths of test specimens are below that specified, shall be at no additional cost to the Owner.

C. Should the strength of test cylinders fall below 60 percent of the required minimum 28 day strength, the concrete shall be rejected and shall be removed and replaced at no additional cost to the Owner.

3.12 PATCHING AND REPAIRS

A. It is the intent of these Specifications to require quality work including forming, mixture and placement of concrete and curing so completed concrete surfaces will require no patching or repairs.

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B. As soon as the forms have been stripped and the concrete surfaces exposed: remove fins and other projections; fill recesses left by the removal of form ties; and repair surface defects which do not impair structural strength. Clean all exposed concrete surfaces and adjoining work stained by leakage of concrete.

C. Immediately after removal of forms remove tie cones and metal portions of ties as specified in Section 03100, fill holes promptly upon stripping as follows: Moisten the hole with water, followed by a 1/16-inch brush coat of neat cement slurry mixed to the consistency of a heavy paste. Immediately plug the hole with a 1 to 1.5 mixture of cement and concrete sand mixed slightly damp to the touch (just short of "balling"). Hammer the grout into the hole until dense, and an excess of paste appears on the surface in the form of a spider web. Trowel smooth with heavy pressure. Avoid burnishing. Reference Section 03100 for filling taper tie holes of the alternate form tie system.

D. When filling tie cone holes and patching or repairing exposed surfaces use the same source of cement and sand as used in the parent concrete. Adjust color to match by addition of white cement. Rub lightly with a fine carborundum stone at an age of one to five days if necessary to bring the surface down with the parent concrete. Do not damage or stain the virgin skin of the surrounding parent concrete. Wash thoroughly to remove all rubbed matter.

E. Defective concrete and honeycombed areas as identified by the Engineer shall be repaired at no additional cost to the Owner.

1. Remove honeycomb and defective concrete to sound concrete and 1-inch minimum depth. The sides of all removal and repair areas shall be square.

2. Roughen surface by bushhammering or chiseling to minimum Concrete Surface Profile (CSP) 9 per ICRI Guideline 03732 with minimum ¼-inch amplitude.

3. Thoroughly clean the surface of loose or weakend materials by waterblasting (preferable) or sandblasting.

4. 12 hours before and again immediately prior to the concrete or mortar being deposited, saturate the joints and adjacent concrete surfaces to at least 12-in past the joint with water.

5. Pack the void with either 4,000 psi concrete using ½-inch maximum rock size, SikaTop 123 PLUS (or approved equal), or SikaTop 111 PLUS (or approved equal) extended with aggregate as allowed per the Manufacturer’s recommendations.

6. A form and pour application using a bird’s mouth may be used pending written approval by the Engineer.

F. For very heavy (generally formed) patches, the Engineer may order the addition of pea gravel to the mixture and the proportions modified as follows:

Bid Set April 2017



Material Volumes Weights Cement 1.0 1.0 Sand 1.0 1.0 Pea Gravel 1.5 1.5

G. The Contractor may use a pre-packaged patching compound, such as: Poly-Patch by Euclid Chemical Company; Sikatop 122 Plus by Sika Chemical Corporation or equal only if approved by the Engineer for use and for color match.

3.13 SCHEDULE

A. The following (Table 5) are the general applications for the various concrete classes and design strengths:

TABLE 5

Class Design Strength (psi)

Description

A 2,500 Concrete fill, pipe and duct encasement

D 4,500 Structural concrete.

END OF SECTION

Bid Set April 2017

Electrical and Instrumentation Duct Encasement Concrete 03305 - 1


SECTION 03305 ELECTRICAL AND INSTRUMENTATION DUCT ENCASEMENT

CONCRETE PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and install concrete encasement around underground electrical raceways as shown on the Drawings and as specified herein.

1.2 RELATED WORK

A. Excavation, backfilling, fill and grading are included in Division 2.


C. Concrete joints and joint accessories are included in Section 03250.


E. Modifications to existing concrete are included in Section 03740.

F. Furnishing and installing electrical conduit is included in Division 16.

G. Furnishing and placing polyethylene warning tape in the backfill above encasement is included in Division 16.

PART 2 PRODUCTS

2.1 MATERIALS

A. Cement aggregate and all other concrete components shall be as specified in Section 03300 for Class A concrete except that aggregate size shall not exceed 3/8 inch. Add a minimum of 6 pounds of red coloring pigment per cubic yard of concrete.

B. Encasement concrete reinforcement shall be in accordance with Section 03200. Submission of reinforcing steel mill certifications is not required.

PART 3 EXECUTION

3.1 INSTALLATION

A. Concrete shall conform to the requirements Section 03300 and as specified herein. Concrete shall be tested by the Contractor’s independent testing firm in accordance with the field quality control measures described in Section 03300, with the modification of one set of cylinders for every 150 cubic yards of concrete placed, and as determined by the Owner. The Contractor shall assist in taking samples for such testing.

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Electrical and Instrumentation Duct Encasement Concrete 03305 - 2


B. Provide not less than 4-in of concrete between the outside of a ducts and the earth. Provide not less than 2-in of concrete between adjacent ducts. Forms shall be as specified in Section 03100 for buried concrete.

C. All duct encasement concrete placements shall be continuous between manholes

or handholes and between manholes or handholes and structures.

D. Where duct encasements pass through concrete walls or concrete electrical structures (e.g. manholes, handholes, etc.), concrete encasements shall be extended through and finished flush with the inside surfaces unless otherwise noted. Watertight construction joints with waterstops conforming to Section 03150 shall be provided.

E. Encasements shall be reinforced as and where indicated on the Drawings.

F. Refer to Section 16020 and Drawings for additional installation requirements.

END OF SECTION

Bid Set April 2017

Concrete Finishes 03350 - 1


SECTION 03350

CONCRETE FINISHES

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and finish cast-in-place concrete surfaces as specified herein.

1.2 RELATED WORK


B. Patching and repair of defective and honeycombed concrete is included in Section 03300.

C. Grout is included in Section 03600.

D. Modifications to existing concrete are included in Section 03740.

E. Painting, toppings and special surfaces are included in Division 9.

F. Dampproofing is included in Section 07110.



1. ASTM C144 - Standard Specification for Aggregate for Masonry Mortar


1.4 RESPONSIBILITY FOR CHANGING FINISHES

A. The surface finishes specified for concrete to receive coatings or other finish materials are those required for the proper application of the products specified under other Sections. Where products different from those specified are approved for use determine if changes in finishes are required and provide the proper finishes to receive these products.

B. Perform changes in finishes made to accommodate products different from those specified at no additional cost to the Owner. Submit the proposed new finishes to the Engineer for approval.

Bid Set April 2017



PART 2 PRODUCTS

2.1 MATERIALS

A. Cementitious and component materials required for finishing concrete surfaces: As specified in Section 03300.

PART 3 EXECUTION

3.1 FORMED SURFACES

A. Form removal: Conform to Sections 03100 and 03300.

B. Do not damage edges or obliterate the lines of chamfers or corners when removing the forms or doing any other work adjacent thereto.

C. Clean all exposed concrete surfaces and adjoining work stained by leakage of concrete.

D. Off-Form Finish

1. Remove fins and other projections and fill tie cones and defects as specified in Section 03300.

E. Rubbed Finish

1. Immediately upon stripping forms and before concrete changes color, carefully remove all fins with a hammer. While the surface is still damp apply a thin coat of medium consistency neat cement slurry using bristle brushes to provide a bonding coat within all pits, air holes or blemishes in the parent concrete. Do not coat large areas of the surface with this slurry.

2. Before the slurry dries or changes color, apply a dry (almost crumbly) grout consisting of one volume cement to 1-1/2 volumes of clean masonry sand having a fineness modulus of approximately 2.25 and complying with the gradation requirements of ASTM C144. Apply grout uniformly using damp (neither dripping wet nor dry) pads of coarse burlap approximately 6-in square used as a float. Scrub grout into the pits and air holes to provide a dense mortar in the imperfections to be patched.

3. Allow the mortar to partially harden for one or two hours depending upon the weather. If the air is hot and dry, keep the surface damp during this period using a fine, fog spray. When the grout has hardened sufficiently so it can be scraped from the surface with the perpendicular edge of a steel trowel without damaging the grout in the small pits or holes, cut off all grout that can be removed with a trowel. Grout allowed to remain on the surface too long will get too hard and will be difficult to remove.

4. Allow the surface to dry and rub it vigorously with clean dry burlap to completely remove any dried grout. No visible film of grout should remain after this rubbing. The entire cleaning operation for any area must be completed the day it is started.

Bid Set April 2017



Do not leave grout on surfaces overnight. Allow grout to dry after it has been cut off with the trowel so it can be wiped off clean with the burlap.

5. On the day following the repair of pits, air holes and blemishes, the surfaces again shall be wiped off clean with dry, used pieces of burlap containing old hardened mortar which will act as a mild abrasive. After this treatment, there shall be no built-up film remaining on the parent surface. If, however, a built-up film remains, use a fine abrasive stone to remove all such material without breaking through the surface film of the original concrete. Scrub lightly to remove excess material without working up a lather or mortar or changing the texture of the concrete.

6. Follow the final bagging or stoning operation with a thorough wash-down with stiff bristle brushes to remove extraneous materials from the surface. Spray the surface with a fine fog spray periodically to maintain a continually damp condition for at least 3 days after the application of the repair grout.

7. The Rubbed Finish application may be deleted by the Engineer if the unfinished

concrete surface is of superior quality and without surface voids.

3.2 FLOORS AND SLABS

A. Consider the potential for longer setting time in concrete containing fly ash.

B. Compact with internal vibrators as specified in Section 03300 and screed to the established grades. Provide floors and slabs level with a tolerance of 1/8 inch when checked with a 12-foot straightedge, except where drains occur, in which case pitch floors to drains as indicated. Failure to meet either of above shall be cause for removal, grinding, or other correction as directed by the Engineer, at no additional cost to the Owner.

C. Following screeding as specified above, float the slabs as approved by the Engineer. Continue floating operation until sufficient mortar is brought to the surface to fill all voids. Test the surfaces with a straightedge to detect high and low spots which shall be eliminated. Do not overwork the concrete as evidenced by excess water and fine material on the surface.

D. Do not use "jitterbugs" or other special tools designed for the purpose of forcing the coarse aggregate away from the surface and allowing a layer of mortar to accumulate on any slab finish. Do not dust surfaces with dry materials. Round off all edges of slabs and tops of walls with a steel edging tool. Use steel edging tool with radius of ¼ inch for all slabs subject to wheeled traffic.

E. Measure floor flatness the day after a concrete floor is finished and before the shoring is removed, in order to eliminate any effects of shrinkage, curling and deflection. A 12- foot long straightedge shall be supported at each end with steel gauge blocks whose thickness are equal to tolerance specified. Floor surface shall not have crowns so high as to prevent 12 feet straightedge from resting on the two end blocks, nor low spots so low that a third block of twice the tolerance in thickness can pass under the supported straightedge. Compliance with the designated limits in four of five consecutive

Bid Set April 2017



measurements will confirm compliance, unless obvious faults are observed. A check for adequate slope and drainage will also be made to confirm compliance.

F. Descriptions

1. Steel Trowel Finish. Finish by screeding and floating with straightedges to bring the surfaces to the elevations indicated. While the concrete is still green, but sufficiently hardened to bear a person's weight without deep imprint, the surface shall be wood floated to a true, even plane with no coarse aggregate visible. Apply sufficient pressure on the wood floats to bring moisture to the surface. After surface moisture has disappeared, hand steel trowel to produce a smooth, impervious surface, free from trowel marks. Trowel the surface again for the purpose of burnishing. The final troweling shall produce a ringing sound from the trowel. Do not use dry cement or additional water in troweling.

2. Wood Float Finish. Finish by screeding with straightedges to bring the surfaces to the elevations indicated. Use a wood float to compact and seal surface. Remove all laitance and leave a clean surface.

3. Light Broomed Finish. Steel trowel finish the concrete, as specified above but omit the final troweling and finish the surface by drawing a fine-hair broom lightly across the surface. Broom in the same direction and parallel to expansion joints, or in the case of inclined slabs, perpendicular to the slope, or except as directed otherwise.

4. Broomed Finish. Steel trowel finish the concrete, as specified above but omit the final troweling. While the concrete is still soft enough, finish the surface with a stiff coarse fiber broom to produce the pattern and depth of scoring as approved by the Engineer.

5. Power Machine Finish. In lieu of hand steel trowel finishing, an approved power machine for finishing concrete floors and slabs may be used in accordance with the directions of the machine manufacturer and as approved by the Engineer. Do not use a power machine until the concrete has attained the necessary set to allow finishing without introducing high and low spots in the slab. Hand steel trowel the areas of slabs not accessible to power equipment. Provide a final steel troweling done by hand over all areas.

3.3 APPROVAL OF FINISHES

A. All concrete surfaces, when finished, will be inspected by the Engineer.

B. Refinish or rework unsatisfactory finishes until approved by the Engineer, at no additional cost to the Owner.

C. Hardened unsatisfactory finishes will require removal, grinding, or other appropriate correction approved by the Engineer, at no additional cost to the Owner.

3.4 SCHEDULE OF FINISHES

A. Finish concrete in the various specified manners either to remain as natural concrete or to receive an additional applied finish or material under another Section. Where

Bid Set April 2017



products different from those specified are approved for use comply with the requirements of Paragraphs 1.04A and 1.04B.

B. Finishes to the base concrete for the following conditions shall be as scheduled below and as further specified herein:

1. Exposed exterior concrete excluding slabs and walking surfaces - Rubbed finish. (Rub open tank walls above and to 1-ft below normal water line).

2. Exposed interior concrete including underside slabs, beams and stairs and sides of openings, beams and stairs - Rubbed finish.

3. Concrete for interior walking surfaces excluding stairs - Wood float finish.

4. Tops of curbs and pads - Steel trowel finish.

5. Concrete on which liquids flow or are contained - Steel troweled finish.

6. Concrete not exposed in the finished work and not scheduled to receive an additional applied finish or material - Off-form finish at vertical surfaces, consolidate and screed to grade at horizontal surfaces.

7. Concrete to receive dampproofing - Off-form finish.

END OF SECTION

Bid Set April 2017




Bid Set April 2017

Shotcrete 03360 - 1


SECTION 03360

SHOTCRETE

PART 1 GENERAL 1.1 SUMMARY

A. Furnish all labor, materials, equipment and incidentals required and install wet-mix

shotcrete foundation complete as indicated and as specified. Comply with applicable requirements of Section 03300 and the additional requirements specified herein.

B. Related Sections. See Related Sections for additional requirements applicable to this

Section (typical).

1. Concrete reinforcement is included in Section 03200.

2. Concrete joints and joint accessories are included in Section 03250.

3. Cast-in-place concrete is included in Section 03300.

4. Concrete finishes are included in Section 03350.

5. Adhesive dowels are included in Section 05500.

1.2 REFERENCES


1. ASTM C31 – Standard Practice for Making and Curing Concrete Test Specimens in the Field

2. ASTM C33 – Standard Specification for Concrete Aggregates

3. ASTM C42 – Standard Test Method for Obtaining and Testing Drilled Cores and

Sawed Beams of Concrete

4. ASTM C94 – Standard Specification for Ready Mixed Concrete

5. ASTM C142 – Standard Test Method for Clay Limps and Friable Particles in Aggregates

6. ASTM C143 – Standard Test Method for Slump of Hydraulic-Cement Concrete

7. ASTM C150 – Standard Specification for Portland Cement

8. ASTM C156 – Standard Test Method for Water Retention by Concrete Curing

Materials

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Shotcrete 03360 - 2


9. ASTM C172 – Standard Practice for Sampling Freshly Mixed Concrete

10. ASTM C231 – Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

11. ASTM C260 – Standard Specification for Air-Entraining Admixtures for Concrete

12. ASTM C309 – Standard Specification for Liquid Membrane-Forming Compounds for

Curing Concrete

13. ASTM C494 – Standard Specification for Chemical Admixtures for Concrete

14. ASTM C618 – Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Concrete

15. ASTM C1140 – Standard Practice for Preparing and Testing Specimens from

Shotcrete Test Panels

16. ASTM D4791 – Standard Test Method for Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate

17. And all applicable standards as outlined in Section 03300, Paragraph 1.04.


1. ACI 506R - Guide to Shotcrete

2. ACI 506.2 – Specification for Materials, Proportioning, and Application of Shotcrete

3. ACI CP-60 – Craftsman Workbook for ACI Certification of Shotcrete Nozzleman

4. And all applicable standards as outlined in Section 03300, Paragraph 1.04.

D. Where reference is made to one of the above standards, the revision in effect at the

time of bid opening shall apply. 1.3 SUBMITTALS

A. Mix design and test data for shotcrete in accordance with Section 03300, 10 days

minimum prior to shooting of preconstruction test panels.

B. Product data for proprietary materials and items, including reinforcement and forming accessories, admixtures, patching compounds, and curing compounds.

C. Submit shotcrete work experience record of each nozzleman and foreman to be

employed on the project as specified.

D. Submit nozzleman certification in accordance with ACI CP-60 and include the name of the certifying agency and certification date.

E. Concrete reinforcement shop drawings in accordance with Section 03200.

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Shotcrete 03360 - 3


F. Procedures: Description of proposed shotcrete process and locations of construction joints.


A. Perform work in accordance with ACI 506.2.

B. Shotcrete quality assurance shall comply with the requirements of Section 03300, Paragraph 1.05 and as specified herein.

C. The Contractor shall engage an independent laboratory at the Contractor’s expense to

provide required submittal data including shotcrete mix design tests and nozzleman prequalification panel tests.

D. Field testing and inspection services of production work will be provided by a Testing

Agency engaged by the Owner, and be in accordance with Section 03300 and as specified herein. The cost of the testing and inspection, except as specifically stated otherwise, will be paid by the Owner. Materials and installed work may require testing and retesting at any time during the work. The Contractor shall be responsible for the cleanup and disposal of testing waste at the project site.

E. Applicator Qualifications: Shotcrete construction shall be performed by an established

company having minimum 5 years’ previous experience with shotcrete, not including swimming pools.

1. Any individual applying shotcrete shall be certified as an ACI Shotcrete Nozzleman by

the American Concrete Institute as outlined in ACI Certification Publication CP- 60.

2. Shotcrete nozzleman shall have a minimum of 2 years’ experience on similar applications and shall be able to demonstrate by the tests specified in Paragraph 1.04.F the ability to satisfactorily gun shotcrete of the required quality.

3. Foreman supervising the placing of shotcrete shall have a minimum of 3 years’

experience as a nozzleman.

F. Shotcrete Prequalification Test Panels:

1. Provide mock-up shotcrete test panels for evaluation of materials and workmanship prior to commencement of work.

a. Each application crew performing production shotcrete work shall prepare a full

set of three test panels in accordance with ASTM C1140.

b. Each test panel shall be a minimum of 3 feet square by the depth of the new shotcrete wall that is to be shot.

c. Reinforce the test panels to reproduce the areas specified on the Drawings.

d. Use the shotcrete mix design that will be used in production to shoot the test

panels.

e. Shoot the test panel at the same angle as will be used in production.

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Shotcrete 03360 - 4


2. The independent testing laboratory shall take six 3-inch diameter core specimens from each test panel for testing.

a. Three of the six cores in each panel shall be taken through reinforcing steel.

1. The Testing Agency will inspect these cores for voids behind reinforcing bars

and assign an average grade for each application crew in accordance with ACI 506.2 Section 1.7. An average grade of 2.0 or less in accordance with ACI 506.2 will be considered acceptable.

2. Application crews that prepare test panels indicating improper consolidation

of shotcrete or voids behind reinforcing bars (average grade of greater than 2.0) shall not be permitted to perform production work unless tests on additional panels are successful.

b. The remaining three cores in each panel shall be taken through unreinforced

sections in the panels and shall be tested for compressive strength in accordance with ASTM C42 and Section 03300.3.09.A.

1. The three cores shall be tested for compressive strength at 28 days and

their average must equal or exceed 100% of the specified compressive strength, with no individual core shall have a compressive strength less than 90 percent of the compressive strength. The tested compressive strength shall incorporate correction factors per ASTM C42 as appropriate.

2. Application crews who prepare test panels that do not meet the strength

requirements shall not be permitted to perform production work unless tests on additional panels are successful.


A. As specified in Section 03300, Paragraph 1.06.

PART 2 PRODUCTS

2.1 GENERAL

A. The use of manufacturer's name and model or catalog number is for the purpose of

establishing the standard of quality and general configuration desired.

B. Like items of materials shall be the end products of a single manufacturer in order to provide standardization for appearance, maintenance and manufacturer's service.

2.2 MATERIALS

A. Materials shall comply with Section 03300 and ACI 506.2, except as specified herein.

B. Cement: Domestic Portland cement conforming to ASTM C150, Type II, Low Alkali. Air

entraining cements shall not be used. Cements produced by a manufacturer that uses hazardous waste derived fuel as an energy source for its kilns shall not be used.

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Shotcrete 03360 - 5


Cement brand must be approved by the Engineer, and one brand shall be used throughout the work.

C. Aggregates: Provide washed, cleaned aggregate and as specified in Section 03300,

Paragraph 2.01, with maximum coarse aggregate conforming to ASTM C33 Size No. 8. Test aggregates for potential alkali reactivity as specified in Section 03300.

D. Water: Potable water free of oil, acid, alkali, salts, chlorides, organic matter, or other

deleterious substances.

E. Admixtures: As specified in Section 03300, Paragraph 2.02. Proportion admixtures according to the manufacturer's recommendations. Two or more admixtures specified may be used in the same mix provided that the admixtures in combination retain full efficiency and have no deleterious effect on the concrete or on the properties of each other.

2.3 MIXES

A. Develop and test shotcrete mix designs with the assistance of an independent testing

laboratory engaged by and at the expense of the Contractor.

B. Select proportions of ingredients to meet the design strength and materials limits and to produce shotcrete having proper placability, good compaction, low percentage of rebound, durability, strength, appearance, and is stiff enough not to sag.

C. Proportion shotcrete mixes by preconstruction testing in accordance with ACI 506R

Chapter 6 and ACI 506.2.

1. Minimum compressive strength: 4,000 psi

2. Slump: 1-1/2-in min to 3-in max as measured by ASTM C143

3. Water cement ratio: 0.44 max, with water kept to a minimum to obtain shotcrete which is as dense and watertight as possible. The proportion of water to cement shall be controlled to produce thorough and uniform hydration of the shotcrete, which when shot will form a homogeneous mass containing neither sags nor dry sand formations.

4. Use a combination of 70 to 80 percent fine aggregate and 20 to 30 percent coarse

aggregate per cubic yard of concrete.

5. Total air content shall be 3.0 to 5.5 percent in the resulting shotcrete.

D. Compression Tests: Provide compression strength testing for approval of the mix design per paragraph 1.03A and in conformance with ACI 506.2.

E. Entrained air, as measured by ASTM C231.

1. If the air-entraining agent proposed for use in the mix requires testing methods

other than ASTM C231 to accurately determine air content, make special note of this requirement in the admixture submittal.

Bid Set April 2017

Shotcrete 03360 - 6


PART 3 EXECUTION 3.1 EXAMINATION AND PREPARATION

A. Prepare soil subgrade in accordance with the Drawings and Specifications.

B. Remove all loose material, dirt, and mud from concrete surfaces by waterblasting to

expose the existing concrete surface.

C. Roughen existing concrete surfaces to receive new shotcrete to minimum ¼ inch amplitude by bushhammering or chiseling.

D. Determine, provide, and install accessories such as expansion bolts and adhesive

anchors in conjunction with fittings and hardware to support the reinforcement from the concrete surfaces providing the spacing and clearances indicated and prevent its displacement during the erection of the reinforcement and placement of shotcrete.

E. Verify correct placement of reinforcement with sufficient clearances to permit complete

encasement. Remove mill scale, rust, and oil per ACI 506R prior to shotcrete placement.

F. Ensure easy access to shotcrete surfaces for screeding and finishing, and to permit uninterrupted application.

G. Determine operating procedures for placement in close quarters, extended distances, or

around unusual obstructions where placement velocities and mix consistency may require adjustment during application.

H. Twelve hours before and again shortly before the shotcrete is placed, saturate existing

concrete surfaces. Remove all standing water before shotcrete placement. 3.2 ALIGNMENT CONTROL

A. Shooting wires shall be installed and tensioned to establish uniform and correct

thickness of shotcrete. Shooting wires shall be spaced at 2-feet on center around the perimeter of the work. Remove wires and fill low spots left by wires prior to final finishing.

B. Install shooting wires at corners and offsets not established by forms.

C. Tighten shooting wires true to line. Position adjustment devices to permit additional

tightening. 3.3 PLACEMENT OF SHOTCRETE

A. Method of shotcreting shall be the wet-mix process.

B. Place reinforcement and shotcrete in accordance with ACI 506.2

B. Place shotcrete only in the presence of the designated Special Inspector.

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Shotcrete 03360 - 7


C. Provide mixing equipment capable of thoroughly mixing all ingredients in sufficient quantity to maintain placing continuity and provide adequate production rates.

D. Time between batching of wet-mix shotcrete material and shooting it shall comply with the

requirements of Section 03300 Paragraph 2.02.C.9.

E. Achieve maximum compaction with minimum rebound. Direct intermittently flowing shotcrete away from the work until flow again becomes consistent.

F. Build-up to required thickness in multiple passes to achieve layering.

1. Except when enclosing reinforcing steel, the nozzle shall be held at right angles to the

surface to be shotcreted and at a distance from 2-1/2 to 3 feet. When enclosing reinforcing steel, the nozzle shall be held so as to direct the material behind the bars. Each side of each bar shall be shot separately.

G. Vertical walls shall be gunned from the bottom up. Thickness of shotcrete layers in

vertical applications shall be limited so as to prevent sag. Keep top surface of thick layers at about 45 degrees’ slope. Any deposit of loose sand or rebound shall be removed prior to placing of any original or succeeding layers of shotcrete.

H. Shotcrete shall not be placed when: 1) the wind is more than 20 mph or if wind causes

separation of ingredients when shooting, 2) when moist inclement conditions prevail, and 3) when ambient temperature approaches freezing and the work cannot be protected.

I. Completely encase reinforcement with sound shotcrete. A second experienced nozzleman

(blowpipe operator) equipped with an air jet shall attend the operator whenever reinforcing steel is being enclosed and shall precede the nozzle and blow out all rebound and sand which may have lodged behind the steel.

J. When a layer of shotcrete is to be covered by a succeeding layer, it shall be first allowed to

harden or stiffen.

K. Remove overspray and rebound (preferably before it hardens) by a blowpipe operator or brooming; remove overspray and rebound that has taken final set by sandblasting, then clean surface with air or water jet. Cut out rebound pockets, unbonded areas, sags, or other defects and replace with new shotcrete. Apply succeeding layer to dampened preceding layer.

L. Should rebound pockets, sags, sloughing, or other defects occur in the work, they shall be

cut out and replaced as directed by the Engineer at the Contractor’s expense.

M. At the end of the day's work, or similar stoppage period, the shotcrete shall be sloped off at an angle of approximately 45 degrees. Thoroughly clean and saturate sloped portions by means of air and water blasting before placing subsequent layers.

N. Place construction joints only at locations shown on the Drawings or as approved by the

Engineer. Any additional or relocation of construction joints proposed by the Contractor shall be submitted to the Engineer for written approval. The Contractor shall have backup equipment on site so that work will not be interrupted.

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Shotcrete 03360 - 8


O. Puddle shotcrete, where air pressure is reduced and water content of the mix increased to facilitate the placing in difficult locations, will not be permitted. Shotcrete shall not be placed where the stream from the nozzle cannot directly impinge on the surface on which the shotcrete is to be placed. Where shooting conditions are difficult, the specified results shall be obtained by maintaining normal air pressure and water ratio and reducing the supply of material.

P. Finish surface of final layer with “gun” finish, with surface variations not exceeding

¼-inch in 5 feet.

Q. Curing Shotcrete

1. Exterior-applied shotcrete: Intermediate layers of shotcrete applied shall be water cured in accordance with Section 03300 for 7 consecutive days. The final layer of shotrcrete applied shall be water cured or liquid membrane cured in accordance with Section 03300 for 7 consecutive days. If the lining is built up in coats, each time a new coat is applied, a new 7-day curing period begins, superseding the curing schedule on prior coats.

3. If shotcreting is not started until the temperature is 40 degrees F and rising, and is

terminated when the temperature is 40 degrees F and falling, no special provisions need be made for protecting the shotcrete against low temperatures. Shotcrete placed below these temperatures shall be protected in accordance with ACI 506R. Shotcrete shall not be placed on frozen surfaces. Shotcrete with strength lower than specified due to cold weather shall be removed and replaced with sound material.

R. Patching and Repairing Shotcrete

1. Dry patches, slugs, sags, sloughs, voids, sand pockets, rebound pockets, or other

defects shall be removed and repaired at the direction of and to the satisfaction of the Engineer.

3.3 FIELD TESTING

A. The Testing Agency will take four 3-inch diameter cores from the production test panels as

described below. The Testing Agency will test these cores for compressive strength and inspect them for voids behind reinforcing bars in accordance with Section 1.04.F.2 herein. A grade of 2.0 or less in accordance with ACI 506.2 will be considered acceptable.

B. Production Test Panels: A minimum of one production test panel for each 50 cubic yards

of shotcrete, and at least one panel per shift for each nozzleman, shall be made during the progress of the work. Additional panels shall be made if deemed necessary by the Engineer. The test panels shall be made from the shotcrete as it is being placed and shall, as nearly as possible, represent the material being applied. The method of making the test samples shall be as follows:

1. Provide a rectangular frame 2-feet-6-inch square by depth of shotcrete to be placed.

The frame shall be secured to a plywood panel and hung or placed in the location where shotcrete is being placed. One half of the panel shall contain the same

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Shotcrete 03360 - 9


reinforcement of the structure and the other half of the panel shall be unreinforced. This form shall be filled in layers simultaneously with the nearby application.

2. Field cure the panels in the same manner as the work.

3. Take a minimum of three samples for compressive strength testing from the

unreinforced half. Obtain and test these samples in accordance with ASTM C42 with minimum core diameter of 3 inches. Average compressive strength of cores taken from each test panel shall be equal to or exceed 85 percent of the specified compressive strength, with no individual core less than 75 percent of the specified compressive strength.

4. Take one sample that includes reinforcing from the reinforced half. These samples will

be graded for visual defects to determine conformance to these Specifications.

C. Wet mix sampling: Collect samples of fresh shotcrete per ASTM C31 and ASTM C172 to perform air content and slump tests as specified in Section 03300.3.09. Perform one air content and one slump test per day of shotcrete application.

D. Special inspection of reinforcing steel shall include confirmation of bar size, bends, and

placement, and adequacy of tying and support.

E. Remove production test panels from work after cores have been taken. 3.4 SHOTCRETE ACCEPTANCE

A. The Engineer has the authority to accept or reject the shotcrete work based on his

observations or those of the Testing Agency. Shotcrete not conforming to the project specifications may be rejected either during the shotcrete application process, or on the basis of testing of cores from test panels or the completed work.

B. Shotcrete not conforming to the specified strength requirements will be rejected.

C. The following deficiencies observed during shotcrete application constitute a cause for

shotcrete rejection:

1. Failure to control and remove build-up of overspray and rebound

2. Inadequate consolidation/coverage around reinforcing steel with shotcrete

3. Presence of voids, delaminations, sags, or sloughing

4. Failure to apply shotcrete to the required line and grade and tolerance

D. Whenever practical, correct deficiencies as directed by the Engineer while shotcrete is still plastic.

E. The following deficiencies observed of hardened shotcrete work constitute a cause for

shotcrete rejection:

1. Finished flatness outside of tolerance

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2. Excessive plastic or drying shrinkage as evidenced by cracking greater than 0.010-inch in width

3. Surface tears or featheredging

4. Presence of delaminations, sags, or sloughing

F. Non-compliance of shotcrete with these Specifications as evidenced in shotcrete

production test panels or assessment of the plastic or hardened shotcrete are grounds for the Engineer to implement a program of evaluation of the in-place shotcrete. Evaluation shall include, but not be limited to:

1. Extraction of cores, either including reinforcement or without reinforcement, as

directed by the Engineer for the purposes of evaluating shotcrete compressive strength and/or shotcrete consolidation around reinforcement

2. Non-destructive testing to check for delaminations or uniformity of compressive

strength

G. Negative results from Production Test Panel: When shotcrete does not meet the specified requirements and was taken from a production test panel, additional samples shall be taken from the area of work in place represented by the test panel and tested for conformance to the specifications as directed by the Engineer. Shotcrete not meeting the specified requirements shall be removed and new shotcrete shall be provided.

H. Negative results from Work in Place: When shotcrete does not meet specified

requirements and was taken from work in place, additional samples shall be taken from the area of work in place and tested for conformance to the specifications as directed by the Engineer. Shotcrete not meeting the specified requirements shall be removed and new shotcrete shall be provided.

I. Shotcrete not in conformance with these specifications shall be removed and replaced by

the Contractor at no cost to the Owner. 3.5 CLEANUP

A. Keep premises clean during the progress of the Work. Remove all waste, refuse, debris,

samples, and mock-up panels upon completion of the Work. 3.6 FAILURE TO MEET REQUIREMENTS

A. As outlined herein and in Section 03300.3.11.

END OF SECTION

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Grout 03600 - 1


SECTION 03600

GROUT

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and install grout complete as shown on the Drawings and as specified herein.

B. Perform all sampling and furnish all testing of materials and products by an independent testing laboratory acceptable to the Engineer but engaged by and at the expense of the Contractor.

1.2 RELATED WORK

A. Demolition and removals are included in Section 02050.


C. Concrete reinforcement is included in Section 03200.

D. Concrete joints and joint accessories are included in Section 03250.

E. Cast-in-place concrete is included in Section 03300.

F. Modifications to existing concrete are included in Section 03740.

G. Miscellaneous metals are included in Section 05500.

1.3 SUBMITTALS

A. Submit, in accordance with Section PR-9, shop drawings and product data showing materials of construction and details of surface preparation, mixing and installation for:

1. Commercially manufactured non-shrink cementitious grout. Include catalog cuts, technical data, storage requirements, product life, working time after mixing, temperature considerations, conformity to the specified ASTM standards, and Material Safety Data Sheet.

2. Commercially manufactured non-shrink epoxy grout. Include catalog cuts, technical data, storage requirements, product life, working time after mixing, temperature considerations, conformity to the specified ASTM standards, and Material Safety Data Sheet.

3. Cement grout. Include the type and brand of cement, the gradation of fine aggregate, product data on any proposed admixtures and the proposed grout mix.

4. Concrete grout. Include data as required for concrete as delineated in Section 03300 and for fiber reinforcement as delineated in Section 03200.

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B. Samples

1. Submit samples of commercially manufactured grout products when requested by the Engineer.

2. Submit samples of aggregates proposed for use in grout mixes when requested by the Engineer.

C. Laboratory Test Reports

1. For concrete grout, submit laboratory test data as required for concrete as delineated in Section 03300.

D. Certifications

1. Certify that the Contractor is not associated with the independent testing laboratory, nor does the Contractor or its officers have a beneficial interest in the laboratory.

E. Qualifications

1. Submit documentation that grout manufacturers have a minimum of 10 years of experience in the production and use of the grouts proposed.

2. Independent Testing Laboratory

a. Name and address

b. Names and positions of principal officers and the name, position, and qualifications of the responsible registered professional engineer in charge.

c. Listing of technical services to be provided. Indicate external technical

services to be provided by other organizations.

d. Names and qualifications of the supervising laboratory technicians.

e. Statement of conformance provided by evaluation authority defined in ASTM C1077. Provide report prepared by evaluation authority when requested by the Engineer.

f. Submit as required above for other organizations that will provide external

technical services.



1. ASTM C33 - Standard Specification for Concrete Aggregates

2. ASTM C150 - Standard Specification for Portland Cement

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3. ASTM C531 - Standard Test Method for Linear Shrinkage and Coefficient of Thermal Expansion of Chemical-Resistant Mortars, Grouts and Monolithic Surfacings and Polymer Concretes

4. ASTM C579 - Standard Test Methods for Compressive Strength of Chemical-

Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Concretes

5. ASTM C827 - Standard Test Method for Change in Height at Early Ages of Cylindrical Specimens of Cementitious Mixtures

6. ASTM C1077 - Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation

7. ASTM C1107 - Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Non-shrink)

8. ASTM E329 - Standard specification for agencies engaged in the testing and/or inspection of materials used in construction



A. Qualifications

1. Grout manufacturers shall have a minimum of 10 years’ experience in the production and use of the type of grout proposed.

2. The independent testing laboratory shall meet the requirements of ASTM E329 and ASTM C1077 and be acceptable to the Engineer. Laboratories affiliated with the Contractor or in which the Contractor or officers of the Contractor's organization have beneficial interest are not acceptable.

B. Field Testing

1. Field testing of concrete grout will be as specified for concrete in Section 03300.


A. Deliver materials to the jobsite in original, unopened packages, clearly labeled with the manufacturer's name, product identification, batch numbers and printed instructions.

B. Store materials in full compliance with the manufacturer's recommendations. Limit total storage time from date of manufacture to date of installation to six months or the manufacturer's recommended storage time, whichever is less.

C. Remove immediately from the site material which becomes damp, contains lumps, or is hardened and replace with acceptable material at no additional cost to the Owner.

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D. Deliver non-shrink cementitious grout as a pre-portioned blend in prepackaged mixes requiring only the addition of water.

E. Deliver non-shrink epoxy grout as a pre-proportioned, prepackaged, three component system requiring only mixing as directed by the manufacturer.

1.7 DEFINITIONS

A. Non-shrink Grout: A commercially manufactured product that does not shrink in either the plastic or hardened state, is dimensionally stable in the hardened state and bonds to a clean base plate.

PART 2 PRODUCTS

2.1 GENERAL

A. The use of a manufacturer's name and product or catalog number is for the purpose of establishing the standard of quality desired.

B. Like materials shall be the products of one manufacturer or supplier in order to provide standardization of appearance.

2.2 MATERIALS

A. Non-shrink Cementitious Grout

1. Non-shrink cementitious grouts: Conform to ASTM C1107. Grouts shall be portland cement based, contain a pre-proportioned blend of selected aggregates and shrinkage compensating agents and require only the addition of water. Non- shrink cementitious grouts shall not contain expansive cement or metallic particles. The grouts shall exhibit no shrinkage when tested in conformity with ASTM C827.

a. General purpose non-shrink cementitious grout: Conform to the standards

stated above. SikaGrout 212 by Sika Corp.; Set Grout by BASF Building Systems; NS Grout by The Euclid Chemical Co., or equal.

b. Flowable (Precision) non-shrink cementitious grout: Conform to the standards

stated above. Masterflow 928 by BASF Building Systems; Hi-Flow Grout by The Euclid Chemical Co.; SikaGrout 212 by Sika Corp., or equal.

B. Non-shrink Epoxy Grout

1. Non-shrink epoxy grout: Grout shall be pre-proportioned, prepackaged, three component, 100 percent solids system consisting of epoxy resin, hardener and blended aggregate. It shall have a compressive strength of 10,000 psi in 7 days when tested in conformity with ASTM C579 and have a maximum coefficient of thermal expansion of 30 x 10-6 inches/inches/degrees F when tested in conformity with ASTM C531. Masterflow 648 CP by BASF Building Systems; Sikadur 42 Grout-Pak by Sika Corp.; E3-G Epoxy Grout by the Euclid Chemical Co. or equal.

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C. Cement Grout

1. A mixture of one part portland cement conforming to ASTM C150, Type II and two parts sand conforming to ASTM C33 with sufficient water to place the grout. The water content shall be sufficient to impart workability to the grout but not to the degree that it will allow the grout to flow.

D. Concrete Grout

1. Conform to the requirements of Section 03300 except as specified herein. Proportion with Type II cement, coarse and fine aggregates, water, water reducing admixture and air entraining agent to produce a mix having an average compressive strength of 3,500 psi at 28 days. Coarse aggregate size shall be 3/8 inch maximum. Slump shall not exceed 5-in. Minimum cement content shall be 540 pounds per cubic yard and maximum water to cement ratio shall be 0.42.

2. Add synthetic reinforcing fibers as specified in Section 03200 to the concrete grout mix at the rate of 1.5 pounds of fibers per cubic yard of grout. Add fibers from the manufacturer's pre-measured bags and according to the manufacturer's recommendations to ensure complete dispersion of the fiber bundles as single monofilaments within the concrete grout.

E. Water

1. Potable water free of oil, acid, alkali, salts, chlorides (except those attributable to drinking water), organic matter, or other deleterious substances.

PART 3 EXECUTION

3.1 PREPARATION

A. Place grout where indicated or specified over existing concrete and cured concrete which has attained its specified design strength unless otherwise approved by the Engineer.

B. Concrete surfaces to receive grout shall be clean and sound; free of ice, frost, dirt, dust, grease, oil, form release agent, laitance and paints and free of all loose material or foreign matter which may affect the bond or performance of the grout.

C. Intentionally roughen concrete surfaces that will receive concrete grout to Concrete Surface Profile (CSP) 9 per ICRI 03732 with 1/4-in minimum amplitude. This roughened surface may be achieved by raking plastic concrete or by bushhammering or chiseling hardened concrete. Remove loose or broken concrete by water blasting or sandblasting. Irregular voids or projecting coarse aggregate need not be removed if they are sound, free of laitance and firmly embedded into the parent concrete. Air compressors used to clean surfaces in contact with grout shall be the oilless type or equipped with an oil trap in the air line to prevent oil from being blown onto the surface.

D. Remove all loose rust, oil or other deleterious substances which may affect the bond or performance of the grout from metal embedments or bottom of baseplates prior to the installation of the grout.

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E. Wash concrete surfaces clean and then keep moist for at least 24 hours prior to the placement of non-shrink cementitious or cement grout. Saturation may be achieved by covering the concrete with saturated burlap bags, use of a soaker hose, flooding the surface or other method acceptable to the Engineer. Upon completion of the 24 hour period, remove visible water from the surface prior to grouting.

F. Non-shrink epoxy grouts do not require saturation of the concrete substrate. Do not wet

concrete surfaces to receive non-shrink epoxy grout. Surfaces in contact with epoxy grout shall be completely dry before grouting.

G. Provide forms for grout. Line or coat forms with release agents recommended by the grout manufacturer. Provide forms anchored in place and shored to resist the forces imposed by the grout and its placement.

1. Forms for all grout other than concrete grout shall be designed to allow the formation of a hydraulic head and shall have chamfer strips built into forms.

H. Level and align the structural or equipment bearing plates in accordance with the structural requirements or the recommendations of the equipment manufacturer, as applicable.

I. Support equipment during alignment and installation of grout by shims, wedges, blocks or other approved means. The shims, wedges and blocking devices shall be prevented from bonding to the grout by bond breaking coatings and removed after grouting unless otherwise approved by the Engineer. Grout voids created by the removal of shims, wedges and blocks.

3.2 INSTALLATION - GENERAL

A. Mix, apply and cure products in strict compliance with the manufacturer's recommendations and these specifications.

B. Provide staffing and equipment available for rapid and continuous mixing and placing. Keep all necessary tools and materials ready and close at hand.

C. Maintain temperatures of the base plate, supporting concrete, and grout between 40 and 90 degrees F during grouting and for at least 24 hours after placement, until grout compressive strength reaches 1000 psi or as recommended by the grout manufacturer, whichever is longer. Do not allow differential heating or cooling of baseplates and grout during the curing period.

D. Take special precautions for hot weather or cold weather grouting as recommended by the manufacturer when ambient temperatures and/or the temperature of the materials in contact with the grout are outside of the 40 to 90 degrees F range.

E. Install grout to preserve the isolation between the elements on either side of the joint where grout is placed in the vicinity of an expansion or partial contraction joint.

F. Reflect all existing underlying expansion, partial contraction and construction joints through the grout.

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3.3 INSTALLATION - NON-SHRINK CEMENTITIOUS GROUTS AND CEMENT GROUTS

A. Mix in accordance with manufacturer's recommendations. Do not add cement, sand, pea gravel or admixtures without prior approval by the Engineer.

B. Do not mix by hand. Mix in a mortar mixer with moving blades. Pre-wet the mixer and empty excess water. Add pre-measured amount of water for mixing, followed by the grout. Begin with the minimum amount of water recommended by the manufacturer and then add the minimum additional water required to obtain workability. Do not exceed the manufacturer's maximum recommended water content.

C. Placements greater than 3-in in depth shall include the addition of clean, washed pea gravel to the grout mix when approved by the manufacturer. Comply with the manufacturer's recommendations for the size and amount of aggregate to be added.

D. Provide forms as specified in Paragraph 3.01G. Place grout into the designated areas and prevent segregation and entrapment of air. Do not vibrate grout to release air or to consolidate the material. Fill all spaces and provide full contact between the grout and adjoining surfaces. Provide grout holes and vent holes as necessary.

E. Place grout rapidly and continuously to avoid cold joints. Do not place grout in layers. Do not add additional water to the mix (retemper) after initial stiffening.

F. Just before the grout reaches its final set, cut back the grout to the substrate at a 45 degree angle from the lower edge of bearing plate unless otherwise ordered and approved by the Engineer. Finish this surface with a wood float or brush finish.

G. Begin curing immediately after form removal, cutback, and finishing. Keep grout moist and within its recommended placement temperature range for at least 24 hours after placement, until grout compressive strength reaches 1000 psi or as recommended by the manufacturer, whichever is longer. Saturate the grout surface by use of saturated burlap bags, soaker hoses or ponding. Provide sunshades. If drying winds inhibit the ability of a given curing method to keep grout moist, erect wind breaks until wind is no longer a problem or curing is finished.

3.4 INSTALLATION – NON-SHRINK EPOXY GROUTS

A. Mix in accordance with manufacturer's recommendations. Mix full batches only, to maintain proper proportions of resin, hardener and aggregate. Do not vary the ratio of components or add solvent to change the consistency of the grout mix. Do not overmix. Do not entrain air bubbles by mixing too quickly.

B. Monitor ambient weather conditions and contact the grout manufacturer for special

placement procedures to be used for temperatures below 60 or above 90 degrees F.

C. Place grout rapidly and continuously to avoid cold joints. Place grout in lifts in accordance with manufacturer's recommendations.

D. Provide forms as specified in Paragraph 3.01G. Place grout into the designated areas and prevent entrapment of air. Fill all spaces and provide full contact between the grout and adjoining surfaces. Provide grout holes and vent holes as necessary.

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E. Minimize "shoulder" length (extension of grout horizontally beyond base plate). In no

case shall the shoulder length of the grout be greater than the grout thickness.

F. Finish grout by puddling to cover all aggregate and provide a smooth finish. Break bubbles and smooth the top surface of the grout in conformity with the manufacturer's recommendations.

G. Epoxy grouts are self-curing and do not require the application of water. Maintain the formed grout within its recommended placement temperature range for at least 24 hours after placement, until grout compressive strength reaches 1000 psi or as recommended by the manufacturer, whichever is longer.

H. Provide grout control joints as indicated on the Drawings.

3.5 INSTALLATION - CONCRETE GROUT

A. Inspect slabs finished under Section 03350 and scheduled to receive concrete grout. Scarify existing slab surfaces to receive concrete grout. Protect and keep the surface clean until placement of concrete grout.

B. Remove debris and clean the surface by sweeping and vacuuming of all dirt and other foreign materials. Pressure wash the surface. Do not flush debris into tank drain lines.

C. Saturate the concrete surface for at least 24 hours prior to placement of the concrete grout by use of saturated burlap bags, soaker hoses or ponding. Remove excess water just prior to placement of the concrete grout.

D. Steel trowel finish as specified in Section 03350. Cure the concrete grout as specified for cast-in-place concrete in Section 03300.

3.6 SCHEDULE

A. The following list indicates where the particular types of grout are to be used:

1. General purpose non-shrink cementitious grout: Use at all locations where non- shrink grout is indicated on the Drawings, except for base plates greater in area than 3-ft wide by 3-ft long.

2. Flowable (precision) non-shrink cementitious grout: Use under all base plates greater in area than 3-ft wide by 3-ft long. Use at all locations indicated on the Drawings to receive flowable (precision) non-shrink grout. Flowable (precision), non-shrink, cementitious grout may be substituted for general purpose non-shrink cementitious grout.

3. Non-shrink epoxy grout: Use at all locations specifically indicated on the Drawings to receive non-shrink epoxy grout.

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4. Cement grout: Use where indicated on the Drawings.

5. Concrete grout: Use where indicated on the Drawings.

END OF SECTION

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Bid Set April 2017

Modifications to Existing Concrete 03740 - 1


SECTION 03740

MODIFICATIONS TO EXISTING CONCRETE

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required to cut, remove, or otherwise modify parts of existing concrete structures or appurtenances as shown on the Drawings and as specified herein as necessary to complete the work. Work under this Section shall also include bonding new concrete to existing concrete.

1.2 RELATED WORK

A. Tightness testing of liquid retaining structures is included in Section 01480.

B. Demolition and modifications is included in Section 02050.

C. Concrete formwork is included in Section 03100.

D. Concrete reinforcement is included in Section 03200.

E. Concrete joints and joint accessories are included in Section 03250.

F. Cast-in-place concrete is included in Section 03300.

G. Grout is included in Section 03600.

H. Miscellaneous metals are included in Section 05500.

1.3 SUBMITTALS

A. Submit, in accordance with Section PR-9, the following:

1. Manufacturer's technical literature and installation/application instructions for all products.

a. Manufacturer's current printed recommendations and product data sheets for all

products provided under this Section including manufacturers printed performance criteria, product life, working time after mixing, surface preparation and application requirements and procedures, curing, volatile organic compound data, and safety requirements.

b. Material Safety Data Sheets (MSDS) for any materials brought on-site including

all resurfacing system materials, solvents, and abrasive blast media.

c. Storage requirements including temperature, humidity, and ventilation.

Bid Set April 2017



2. Documentation of the qualifications as specified in Paragraphs 1.05D and 1.05E.

B. Submit for adhesive anchoring system manufacturer’s ICC or IAPMO and City of Los Angeles Department of Building and Safety (LADBS) Research report for anchorage to cracked concrete.



1. ASTM C109 - Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 2-in Cube Specimens).

2. ASTM C273 - Standard Test Method for Shear Properties of Sandwich Core Materials.

3. ASTM C881 - Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

4. ASTM C882 - Standard Test Method for Bond Strength of Epoxy-Resin Systems Used with Concrete by Slant Shear.

5. ASTM D412 - Standard Test Methods for Vulcanized Rubber and Thermoplastic Rubbers and Thermoplastic Elastomers – Tension.

6. ASTM D570 - Standard Test Method for Water Absorption of Plastics.

7. ASTM D624 - Standard Test Methods for Tear Strength of Conventional Vulcanized Rubber and Thermoplastic Elastomers.

8. ASTM D638 - Standard Test Method for Tensile Properties of Plastics.

9. ASTM D695 - Standard Test Method for Compressive Properties of Rigid Plastics.

10. ASTM D732 - Standard Test Method for Shear Strength of Plastics by Punch Tool

11. ASTM D751 - Standard Test Methods for Coated Fabrics.

12. ASTM D790 - Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials.

13. ASTM D1042 - Standard Test Method for Linear Dimensional Changes of Plastics Under Accelerated Service Conditions.

14. ASTM D1622 - Standard Test Method for Apparent Density of Rigid Cellular Plastics.

15. ASTM D1623 - Standard Test Method for Tensile and Tensile Adhesion Properties of Rigid Cellular Plastics.

Bid Set April 2017



16. ASTM D2126 - Standard Test Method for Response of Rigid Cellular Plastics to Thermal and Humid Aging.

17. ASTM D2240 - Standard Test Method for Rubber Property – Durometer Hardness.

18. ASTM D2842 - Standard Test Method for Water Absorption of Rigid Cellular Plastics.

19. ASTM D4263 - Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method.

20. ASTM D4541 - Standard Test Method for L.R. Standard Method for Pull-Off Strength of Coatings using Portable Adhesion Testers.

21. ASTM E96 - Standard Test Method for Water Vapor Transmission of Materials.

22. ASTM G109 - Standard Test Method for Determining the Effects of Chemical Admixtures on the Corrosion of Embedded Steel Reinforcement in Concrete Exposed to Chloride Environments.



A. No existing structure or concrete shall be shifted, cut, removed, or otherwise altered until authorization is given by the Engineer.

B. When removing materials or portions of existing structures and when making openings in existing structures, all precautions shall be taken and all necessary barriers, shoring and bracing and other protective devices shall be erected to prevent damage to the structures beyond the limits necessary for the new work, protect personnel, control dust and to prevent damage to the structures or contents by falling or flying debris.

C. Unless otherwise permitted, shown or specified, line drilling will be required in cutting existing concrete.

D. Contractor qualifications. Complete a program of instruction in the application of the approved manufacturer's material and provide certification from the manufacturer attesting to their training and status as an approved applicator.

E. Manufacturer's qualifications. Have a minimum of ten years’ experience within the last ten years in the manufacture and use of the products specified and have an ongoing program of training, certifying and technically supporting the Contractor's personnel.

F. Provide a notarized certificate stating that each material to be provided meets the requirements of this Section and has the manufacturer's current printed literature on the product package or container.

G. The Contractor's supervisor shall have attended a training program sponsored by the manufacturer supplying the materials approved for this project.

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H. A representative of the product manufacturer shall be present for the first three days of installation to give instructions to the installation crew.

I. A representative of the product manufacturer shall make periodic site visits to ensure the product is being installed in accordance with published instructions.

J. Construction tolerances shall be as specified elsewhere in Division 3, except as modified herein and elsewhere in the Contract Documents.

K. The Contractor shall make available all locations and phases of the work for access by the Engineer or other personnel designated by the Engineer. The Contractor shall provide ventilation and safe access to the work.

L. The Contractor is solely responsible for the workmanship and quality of the modification work. Inspections by the manufacturer, the Engineer, or others do not limit the Contractor's responsibility for the quality of the work.

M. Apply the most stringent requirements of other stated specifications, codes, standards,

and this Section when conflicts exist.


A. Delivery of Materials:

1. Deliver all materials in original, new and unopened packages and containers clearly labeled with the following information:

a. Manufacturer's name.

b. Name or title of material, and other product identification.

c. Manufacturer's stock number and batch number.

d. Date of manufacture.

e. Instructions.

f. Expiration or "use by" date.

B. Storage of Materials:

1. Store the products in accordance with the manufacturers' recommendations, and supplementary requirements below.

2. Store only approved materials on site.

3. Store in a suitable location approved by Engineer. Keep area clean and accessible.

4. Restrict storage to repair materials and related equipment.

Bid Set April 2017



5. Comply with health and fire regulations including the requirements of the Occupational Safety and Health Administration (OSHA).

C. Handling of Materials:

1. Handle the products in accordance with the manufacturers' recommendations, and supplementary requirements below.

2. Handle materials carefully to prevent inclusion of foreign materials.

3. Do not open containers or mix components until necessary preparatory work has been completed and application work will start immediately.

PART 2 PRODUCTS

2.1 MATERIALS

A. General

1. Materials shall comply with these Specifications and any state or local regulations.

B. Epoxy Bonding Agent

1. General a. The epoxy bonding agent shall be a two-component, solvent-free, asbestos- free

moisture insensitive epoxy resin material used to bind plastic concrete to hardened concrete and complying with the requirements of ASTM C881, Type II, and the additional requirements specified herein.

2. Material

a. Properties of the cured material 1) Compressive Strength (ASTM D695): 12,200 psi minimum at 28 days. 2) Tensile Strength (ASTM D638): 6900 psi minimum at 7 days. 3) Flexural Strength (ASTM D790 - Modulus of Rupture): 7,000 psi minimum at

14 days. 4) Shear Strength (ASTM D732): 6200 psi minimum at 14 days. 5) Water Absorption (ASTM D570): 0.21 percent maximum at 7 days. 6) Bond Strength (ASTM C882) Hardened to Plastic: 2200 psi minimum at 14

days’ moist cure. 7) Effective Shrinkage (ASTM C883): Passes Test. 8) Color: Gray.

3. Approved Manufacturer

a. Sika Corporation, Lyndhurst, NJ – Sikadur 32, Hi-Mod or equal.

Bid Set April 2017



C. Repair Mortar (Polymer-Modified Portland Cement Mortar)

1. Horizontal Surfaces

a. Repair mortar is a two-component polymer-modified, portland cement, fast- setting, trowel-grade mortar used to repair horizontal surfaces with a migrating corrosion inhibitor.

b. Material

1) Properties of the cured material: a) Compressive Strength (ASTM C109): 7000 psi minimum at 28 days. b) Splitting Tensile Strength (ASTM C496): 750 psi minimum at 28

days. c) Flexural Strength (ASTM C293): 2000 psi minimum at 28 days. d) Freeze/Thaw Resistance (ASTM C666): 300 cycles at 98 percent e) Bond Strength (ASTM C882 Modified) Hardened to Plastic: 2200 psi

minimum at 28 days moist cure. f) Permeability (AASHTO T277): 500 coulombs at 28 days. g) Color: Gray.

c. Approved manufacturers include: Sika Corporation, Lyndhurst, NJ - SikaTop

122 Plus, or equal.

2. Vertical and Overhead Surfaces

a. Repair mortar is a two-component polymer-modified, portland cement, fast setting, non-sag mortar used to repair vertical and overhead surfaces with a migrating corrosion inhibitor.

b. Material

1) Properties of the cured material: 2) Compressive Strength (ASTM C109): 7000 psi minimum at 28 days. 3) Splitting Tensile Strength (ASTM C496): 900 psi minimum at 28 days. 4) Flexural Strength (ASTM C293): 2000 psi minimum at 28 days. 5) Freeze/Thaw Resistance (ASTM C666): 300 cycles at 98 percent. 6) Bond Strength (ASTM C882 Modified) Hardened to Plastic: 2200 psi

minimum at 28 days’ moist cure. 7) Permeability (AASHTO T277): 500 coulombs at 28 days. 8) Color: Gray.

c. Approved manufacturers includes: Sika Corporation, Lyndhurst, NJ - SikaTop

123 Plus, or equal.

3. Deep Repairs at Horizontal, Vertical and Overhead Surfaces

a. Repair mortar is a two-component polymer-modified, portland cement, fast setting, non-sag mortar used to repair horizontal, vertical and overhead surfaces with a migrating corrosion inhibitor.

Bid Set April 2017



b. The repair mortar may be extended with 3/8-inch coarse aggregate in accordance with manufacturer’s recommendations, and may be used in a form and pour application.

c. Approved manufacturers include: Sika Corporation, Lyndhurst, NJ - SikaTop

111 Plus, or equal.

D. Cement Crack Repair Compound

1. Cement crack repair compound shall be a non-shrink, high-bond-strength, hydraulic cement crystalline waterproofing compound for concrete patching and repair. It shall have a minimum compressive strength of 2,100 psi at 24 hours and 4,500 psi at 28 days. The repair compound shall be Xypex Patch’n Plug by Xypex Chemical Corporation, Richmond, BC, Canada, or approved equal.

PART 3 EXECUTION

3.1 GENERAL

A. Cut, remove, repair, or otherwise modify parts of the existing structures or appurtenances, as indicated on the Drawings, specified, or necessary to complete the work. Finishes, joints, reinforcements, sealants, etc., are specified in their respective Sections. All work shall comply with the requirements of this Section and as shown on the Drawings.

B. The locations, details, and limits of the modifications are shown on the Drawings. All work shall comply with the requirements of this Section and as indicated on the Drawings.

C. Examine areas and conditions under which the modifications work is to be installed, and notify Engineer in writing of conditions detrimental to proper and timely completion of work. Do not proceed with work until unsatisfactory conditions have been corrected in a manner acceptable to Engineer.

D. All commercial products shall be stored, mixed, applied and cured in strict compliance with the manufacturer's instructions.

E. When drilling holes for dowels/bolts, stop drilling if reinforcing is encountered. As approved by the Engineer, relocate the hole to avoid reinforcing. Do not cut reinforcing without prior approval by the Engineer. Where possible, identify reinforcing locations prior to drilling using "rebar locators" so that drill hole locations may be adjusted to avoid reinforcing interference.

F. All saw-cut edges for modification areas shall be straight and perpendicular to the plane surface being cut. Intersecting cuts shall be perpendicular to each other.

G. Saw cutting shall stop if rebar is encountered. Rebar shall not be cut without prior approval by the Engineer. Where possible, Contractor shall identify rebar locations within one foot of saw cut locations in any direction prior to saw cutting using "rebar locators."

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H. Clean concrete surfaces of all efflorescence, deteriorated concrete, dirt, laitance, existing repair materials (liners, adhesives, epoxies, etc.), and foreign matter by sandblasting, airblasting, scarifying or other mechanical means to sound original concrete.

I. Care shall be taken to fully consolidate the modification material, completely filling all

portions of the area to be filled.

J. The finished surfaces shall be brought into alignment with the adjacent existing surfaces to provide a uniform, even surface. The modified surfaces shall match adjacent existing surfaces in texture and shall receive any coatings or surface treatments that had been provided for the existing surface.

K. The Engineer may from time to time direct the Contractor to make additional modifications to existing concrete. These modifications shall be made as specified or by such other methods as may be appropriate.

L. Repair or replace concrete shown or specified to be left in place which is damaged as a result of the work by approved means at no additional cost to the Owner.

3.2 CONCRETE REMOVAL

A. Concrete designated to be removed to specific limits as shown on the Drawings or directed by the Engineer, shall be done by line drilling at limits of removal followed by chipping or jack- hammering as appropriate in areas where concrete is to be taken out. Remove concrete in such a manner that surrounding concrete and existing reinforcing to be left in place and existing in place equipment are not damaged. Sawcutting at limits of concrete to be removed shall only be done if indicated on the Drawings, specified herein, or after obtaining written approval from the Engineer.

B. In all cases where the joint between new concrete or grout and existing concrete will be exposed in the finished work, except as otherwise shown or specified, the edge of concrete removal shall be a 1-in deep saw cut on each exposed surface of the existing concrete or as indicated on the Drawings.

C. Concrete specified to be left in place which is damaged shall be repaired by approved means to the satisfaction of the Engineer.

3.3 CONNECTION SURFACE PREPARATION

A. Connection surfaces shall be prepared as specified below for concrete areas requiring patching, repairs or modifications as shown on the Drawings, specified, or as directed by the Engineer.

B. Remove all loose and deteriorated materials, efflorescence, existing repair materials (sealants, adhesives, epoxies, etc.) dirt, oil, grease, and all other bond inhibiting materials from the surface by dry mechanical means, i.e. - sandblasting, chipping, wire brushing, or other mechanical means as approved by the Engineer. Surfaces that will be in contact with freshly placed concrete or concrete grout shall be roughened to minimum Concrete Surface Profile (CSP) 9 per ICRI Guideline 03732 with minimum ¼

Bid Set April 2017



inch amplitude. Thoroughly clean surface of loose or weakened material by sandblasting or airblasting. Irregular voids or surface stones need not be removed if they are sound, free of laitance, and firmly embedded into parent concrete.

C. If reinforcing steel is exposed, it must be mechanically cleaned to remove all loose material, contaminants, rust, etc., as approved by the Engineer. If half of the diameter of the reinforcing steel is exposed, chip out behind the steel. The distance chipped behind the steel shall be a minimum of 1-in. Reinforcing to be incorporated in new concrete and/or repair mortar shall not be damaged during the removal operation.

D. Reinforcing from existing removed or deteriorated concrete which is shown to be incorporated in new concrete and/or repair mortar shall be cleaned by mechanical means to remove all loose material and products of corrosion before proceeding. It shall be cut, bent or lapped to new reinforcing as shown on the Drawings and provided with one-inch minimum cover all around.

E. Prepare concrete surfaces as follows.

1. Adhesive anchoring system shall be used for installation of all reinforcing steel dowels into existing concrete where indicated on Drawings. The installation shall comply strictly with manufacturer's recommendations, including drill bit diameter, surface preparation, injection and installation of dowel. Use oil free compressed air to blast out loose particles and dust from the drilled holes. Dowels shall be clean and free of dirt, oil, grease, ice or other material which would reduce bond. Deformed bars shall be drilled and embedded to the depth indicated on the Drawings. Concrete in all existing structures shall be considered to have a strength of 3000 psi.

2. After the existing concrete surface at connection has been roughened and cleaned, thoroughly saturate with water with no standing water during application. Place new repair mortar as detailed on Drawings. Field preparation and application shall comply strictly with manufacturer's recommendations.

3.4 GROUTING

A. Grouting shall be as specified in Section 03600.

3.5 CRACK REPAIR

A. All concrete cracks in non-liquid-containing structures greater than 0.20-inch in width shall be repaired as directed by the Engineer.

B. All concrete cracks in liquid-containing structures greater than 0.010-inch in width shall be repaired in the following manner:

1. Rout crack by chiseling or chipping a square groove 1-inch wide by a minimum depth of 1-inch (do not use vee-notch). Flush away loose materials and dirt from the cavity with water and a stiff brush.

2. Mix cement repair compound in accordance with the manufacturer’s recommendations.

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3. Form cement plug with gloved hand, pressing firmly into groove until plug is hardened.

C. Should wall cracks in liquid-containing structures leak following cement-repair- compound repair, the cracks shall be repaired by pressure injecting crack sealant through valves sealed to surface with crack repair epoxy adhesive per manufacturer’s recommendations. “Leaking” shall be defined as water flowing or seeping from the structure, or if moisture can be transferred from the exterior surface to a dry hand.

3.6 INSPECTION

A. At completion of all modification and repair work, the Contractor, Engineer, and installers of the materials used on the repairs shall inspect the work. All modifications not in conformance with the Drawings or Specifications shall be repaired in accordance with the manufacturer's instructions at no additional cost to the Owner. At the completion of these repairs, the Contractor, Engineer, and installers of the materials shall inspect the repaired problem areas.

END OF SECTION

Bid Set April 2017

Miscellaneous Metals 05500 - 1


SECTION 05500

MISCELLANEOUS METALS

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and install all miscellaneous metal complete as shown on the Drawings and as specified herein.

1.2 RELATED WORK

A. Cast-in-Place Concrete for installing anchor bolts, steel pipe sleeves, and other items cast into concrete is included in Section 03300.

B. Concrete joint accessories are included in Section 03250.

C. Painting is included in Division 9.

D. Pipe hangers and sleeves are included in Division 15.

E. Equipment anchors are included in the respective Sections of Divisions 11 and 15.

1.3 SUBMITTALS

A. Submit, in accordance with Section PR-9, shop drawings, erection or setting drawings, product data, etc., showing methods of assembly, anchorage and connection to other members. Indicate welded connections in accordance with AWS A2.0. Shop drawings are required for all items included under this Section.

B. Design Data:

1. Submit calculations or test data demonstrating that the railings will resist the loads specified in ASCE 7 at the post spacing provided. Calculations shall be prepared and stamped by a civil or structural engineer registered in the State of California.

C. Test Reports

1. Certified copy of mill test reports on each steel proposed for use showing the physical properties and chemical analysis.

D. Certificates

1. Certify that welders have been qualified under AWS, within the previous 12 months, to perform the welds required under this Section.

Bid Set April 2017



2. Submit certification that the railing system is in compliance with OSHA requirements and the 2013 California Building Code with 2014 Los Angeles Building Code Amendments.

3. Submit Written Welding Procedure Specifications (WPS’s) for each different welded joint proposed for use whether prequalified or qualified by testing.



1. ASTM A36 - Standard Specification for Carbon Structural Steel.

2. ASTM A48 - Standard Specification for Gray Iron Castings.

3. ASTM A53 - Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc- Coated, Welded and Seamless.

4. ASTM A108 - Standard Specification for Steel Bars, Carbon, Cold Finished,

Standard Quality.

5. ASTM A276 - Standard Specification for Stainless Steel Bars and Shapes.

6. ASTM A240 - Standard Specification for Heat-Resisting Chromium and Chromium- Nickel Stainless Plate, Sheet, and Strip Pressure Vessels.

7. ASTM A307 - Standard Specification for Carbon Steel Bolts and Studs, 60,000 Psi Tensile Strength.

8. ASTM A325 - Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength.

9. ASTM A500 - Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes.

10. ASTM A501 - Standard Specification for Hot-Formed Welded and Seamless Carbon Steel Structural Tubing.

11. ASTM A536 - Standard Specification for Ductile Iron Castings.

12. ASTM A570 - Standard Specification for Steel, Sheet and Strip, Carbon, Hot- Rolled, Structural Quality.

13. ASTM A1008 - Standard Specification for Steel, Sheet, Cold-Rolled, Carbon, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, Solution Hardened, and Bake Hardenable.

14. ASTM F593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs.

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15. ASTM F594 - Standard Specification for Stainless Steel Nuts.

16. ASTM F1554 -Standard Specification for Anchor Bolts, Steel, 36, 55, and 105-ksi Yield Strength.

17. ASTM F2329 - Specification for Zinc Coating, Hot-Dip, Requirements for Application to Carbon Screws, Washers, Nuts, and Special Threaded Fasteners

B. American Institute of Steel Construction (AISC)

1. Specification for Structural Steel Buildings

C. American Welding Society (AWS)

1. AWS D1.1 - Structural Welding Code - Steel.

2. AWS D1.6 - Structural Welding Code - Stainless Steel

D. Federal Specifications

1. FS-FF-B-575C - Bolts, Hexagonal and Square

E. Occupational Safety and Health Administration (OSHA)

F. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.


A. The work of this Section shall be completely coordinated with the work of other Sections. Verify, at the site, both the dimensions and work of other trades adjoining items of work in this Section before fabrication and installation of items herein specified.

B. Furnish to the pertinent trades all items included under this Section that are to be built

into the work of other Sections.

C. All welding shall be performed by qualified welders and shall conform to the applicable AWS welding code. Welding of steel shall conform to AWS D1.1 and welding of stainless steel shall conform to AWS D1.6.


A. Deliver items to be incorporated into the work of other trades in sufficient time to be checked prior to installation.

B. Store materials on skids and not on the ground and block up so that they will not become bent or otherwise damaged. Handle materials with cranes or derricks. Do not dump material off cars or trucks nor handle in any other way that will cause damage.

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C. Repair items that have become damage or corroded to the satisfaction of the Engineer prior to incorporating them into the work.


A. Field measurements shall be taken at the site, prior to fabrication of items, to verify or supplement indicated dimensions and to ensure proper fitting of all items.

PART 2 PRODUCTS

2.1 GENERAL

A. The use of manufacturer's name and model or catalog number is for the purpose of establishing the standard of quality and general configuration desired.

B. Like items of materials shall be the end products of one manufacturer in order to provide standardization for appearance, maintenance and manufacturer's service.

2.2 MATERIALS

Unless otherwise noted, materials for miscellaneous metals shall conform to the following standards:

1. Structural Steel: a. Wide flange shapes: ASTM A992. b. Other shapes; plates; rods and bars: ASTM A36

2. Structural Steel Tubing: ASTM A500, Grade B.

3. Welded and Seamless Steel Pipe ASTM A501 or ASTM A53, Type E or S, Grade B Schedule 40. Use standard malleable iron fittings, galvanized for exterior work

4. Ductile Iron Castings: ASTM A536, Grade 65-45-12.

5. Stainless Steel Plates, Sheets, and Washers: ASTM A240, Type 316 (Type

316L for welded components).

6. Stainless Steel Shapes and Bars: ASTM A276, Type 316 (Type 316L for welded components).

7. Stainless Steel Bolts ASTM F593, Type 316.

8. Stainless Steel Nuts: ASTM F594, Type 316.

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9. Carbon Steel Bolts and Studs ASTM A307, Grade A (hot dip galvanized

nuts and washers where noted)

10. High Strength Steel Bolts, Nuts and washers ASTM A325 (mechanically galvanized per

ASTM B695, Class 50, where noted) a. Elevated Temperature Exposure Type I b. General Application Type I or Type II

11. Galvanizing: ASTM A123, Zn w/0.05 percent

minimum Ni.

12. Galvanizing, hardware: ASTM A153, Zn w/0.05 percent minimum

Ni.

13. Galvanizing, anchor bolts: ASTM F2329, Zn w/0.05 percent minimum

Ni.

14. Welding electrodes, steel AWS A5.1 E70xx

2.3 ANCHORS, BOLTS AND FASTENING DEVICES

A. Unless otherwise noted, anchors cast in concrete shall be ASTM F1554, Grade 36. Provide standard headed bolts with heavy hex nuts and Grade A washers. Where galvanized anchors are shown or specified, provide standard headed bolts with heavy hex nuts and Grade A washers, all galvanized in accordance with ASTM F2329.

B. Unless otherwise noted, bolts for the connection of carbon steel or iron shall be steel machine bolts; bolts for the connection of galvanized steel or iron shall be galvanized steel or stainless steel machine bolts; and bolts for the connection of stainless steel shall be stainless steel machine bolts.

C. For structural purposes, unless otherwise noted, post-installed concrete anchors shall be adhesive or expansion type anchors. Post-installed anchors shall have current ICC or IAPMO Evaluation Service Reports and LADBS Research Reports. Post-installed anchors shall be suitable for use in cracked concrete.

1. Unless otherwise noted, expansion anchors shall be zinc plated carbon steel wedge type anchors complete with nuts and washers. Type 316 stainless steel wedge type anchors shall be used where they will be submerged or exposed to the weather or where stainless steel wedge type anchors are shown or specified. When the length or embedment of the bolt is not noted on the Drawings, provide length sufficient to place the wedge and expansion cone portion of the bolt at least 1-in behind the concrete reinforcing steel. Expansion anchors shall be Hilti Kwik- Bolt TZ; Simpson Strong Tie Strong-bolt 2; or equal.

Bid Set April 2017



2. Adhesive anchor system, for fastening to solid concrete substrate, shall be a system manufactured for the installation of post installed studs including anchoring hardware and chemical dispenser. Injection adhesive shall be a two-component epoxy system including a hardener and a resin, furnished in pre-measured side- by-side cartridges which keep the two components separate. Side-by-side cartridges shall be designed to accept a static mixing nozzle which thoroughly blends the two components and allows injection directly into the drilled hole. Provide zinc plated carbon steel or Type 316 stainless steel stud assemblies as indicated on the Drawings consisting of an all-thread anchor rod with nut and washer. Adhesive anchor system shall be Hilti HIT-HY 200-R; Hilti HIT-RE 500 V3; Simpson Strong Tie SET-XP; or equal.

D. Machine bolts and nuts shall conform to Federal Specification FF-B-575C. Bolts and nuts shall be hexagon type. Bolts, nuts, screws, washers and related appurtenances shall be Type 316 stainless steel.

2.4 ACCESS HATCHES

A. The pumping station shall be furnished with Type 316 stainless steel access hatches, complete with hinged and pad-lockable covers.

1. The hatches shall be securely mounted above the pumps and valves. Hatches shall be of single or double cover construction in the minimum sizes shown on the Drawings. Minimum sizes shown refer to the clear opening available with the hatch doors in the open position. The pump manufacturer shall coordinate the actual size of the hatches to be supplied with the pumps furnished. Covers shall be stainless steel 1/4 inch diamond pattern plate reinforced on the underside with welded stiffeners to withstand a 300 psf live load with a maximum deflection of 1/150th of the span. Channel frame shall be 1/4 inch stainless steel with full anchor flange or strap anchors for concrete embedment around the perimeter.

2. Cover(s) shall be equipped with heavy stainless steel hinges with stainless steel pins and shall pivot so cover does not protrude into the channel frame. Hinges shall be through bolted to the cover with tamper proof stainless steel lock bolts and shall be through bolted to the frame with stainless steel bolts and lock nuts. Cover(s) shall be equipped with compression springs enclosed in telescopic tubes. Upper tube shall be the outer tube to prevent accumulation of moisture, grit and debris inside the tube assembly. Lower tube shall interlock with a flanged support shoe fastened to a formed 1/4 inch gusset support plate.

3. Cover(s) shall be fitted with the required number and size of compression spring operators to afford ease of operation through the entire arc of opening and to act as a check in retarding downward motion when being closed. Cover(s) shall be equipped with a hold-open arm which automatically locks the cover in the open position. A conveniently located handle shall release the cover(s) for closing.

4. A stainless-steel snap lock with fixed turn handle shall be mounted on the underside of the cover. A removable exterior latch handle shall be provided and the latch release shall be protected by a flush gasketed removable screw type

Bid Set April 2017



plug or equal. Cover(s) shall have a lift handle that is designed to be flush with the walking surface when not in use. Hardware shall be Type 316 stainless steel, including tubes, springs, lifting, mechanism supports and tube caps, support shoes, hold-open arm(s), hinges, hinge pins, safety chains snap lock and lock strike, and all fasteners. Hold-open arm guide(s) shall be manufactured of stainless steel.

5. Factory finish shall be bead blast finish stainless steel with bituminous coating

applied to the exterior of frame which will be in contact with concrete.

6. Hatches shall be Type J stainless steel or Type JD stainless steel as manufactured by the Bilco Company, Type TPD or TPS as manufactured by

U.S. Foundry & Manufacturing Corporation, or equal product. All hatches shall be of the weathertight design.

B. The vortex manhole shall be furnished with stainless steel access hatches.

1. The watertight (floodtight/gastight) floor access door shall be Model B-AHS as manufactured by U.S.F. Fabrication, Inc. or approved equal, with the size being specified on the plans. Door leaf shall be ¼-inch thick stainless steel diamond plate reinforced for an AASHTO H20-44-wheel load (capable of holding up to 25 feet. head of water). Manufacturer shall provide structural calculations showing that the door design meets the loading requirements of AASHTO H-20-44. The bottom of the cover shall have a continuous groove to securely hold a 9/16-inch diameter EPDM gasket around its perimeter. The cover shall have 316 stainless steel 1/2- by 1-1/4-inch hex head bolts to compress the gasket so that the door will not leak from standing water. The frame shall be 3/8-inch thick material with 3/16- by 1-1/2-inch strap anchors welded around the frame for casting into concrete. The floor access door shall be equipped with a flush floodtight handle that does not protrude above the cover, and a type 316 stainless steel hold open arm with red vinyl grip that automatically keeps the cover in its upright, open position. The door shall have type 316 stainless steel hinges with type 316 stainless steel flat head bolts. The door shall have stainless steel open horizontal springs to assist in opening the cover and reducing the force during closing. Installation shall be in accordance with the manufacturer’s attached instructions. The entire frame including the seat on which the reinforcing rests shall be supported by concrete or other material designed to support the specified load. All parts of the frame in contact with concrete shall have a coating of bituminous paint. An adhesive backed vinyl material that protects the product during shipping and installation shall cover the entire top of the frame and cover. The door shall be manufactured and assembled in the United States. Manufacturer shall guarantee the door against defects in materials and workmanship for a period of ten years.

2.5 GUARDRAILS

A. Guardrail systems shall comply with the requirements of OSHA and CBC with LABC amendments.

Bid Set April 2017



B. Stainless steel guardrails shall be a welded stainless steel pipe system. Post and rails shall be Type 316 stainless steel. Splice and reinforcing sleeves, brackets and caps, etc., shall be Type 316 stainless steel. Fastening hardware shall be Type 316 stainless steel.

C. Guardrails shall be 3 rail welded railing systems, as shown on the Drawings, fabricated with 1-1/2 inches nominal diameter pipe. Posts shall be Schedule 40 pipe, minimum and rails shall be Schedule 40 pipe, minimum. Posts and top rails shall be continuous. Spacing of posts shall not exceed 5 feet 0 inches on center and shall be uniformly spaced except as otherwise shown on the Drawings. All railing posts shall be vertical.

D. Welds shall be circumferential welds ground smooth and even to produce a railing that is neat in appearance and structurally sound. Welding methods shall be in conformity with AWS standards for the materials being joined. All rails to post connections shall be coped and fastened by continuous welds. There shall be no burrs, sharp edges or protrusions on any weld on any part of the rail system. After fabrication, the welds and surrounding area shall be cleaned and hand buffed to blend with the adjacent finish. All mechanical fasteners shall be unobtrusively located in countersunk holes with the top flush with the surface of the rail. Bends in the railing shall be as indicated by the Drawings. No distortion of the circular railing shape will be allowed. Bends and terminal sections shall be made without the use of fittings. Corner bends shall be mitered and welded bends.

E. Railing shall be assembled in sections as long as practical but shall not be greater than 24 feet in length. A field splice shall be used when an assembled section is to be attached to another section.

1. Field splices shall use internal splice sleeves located within 8 inches of guardrail posts. The sleeve shall be welded to the guardrail on one side and fastened with a set screw to the rail on other side. The field splice shall be detailed to take the differential expansion between the guardrail system and the supporting structure.

F. The bases or supports for guardrail posts shall be the types indicated on the Drawings.

1. Where non-removable railing is set in concrete, the posts shall be placed in

2-1/2 inches diameter formed concrete openings and firmly caulked with cement grout. Collars shall be placed around the post bases and fastened in place with set screws on the side of the post away from the walkway. Posts shall be placed with the centerline 6 inches from the edge of the concrete except that posts shall be set at the centerline of concrete curbs.

2. Stainless steel guardrail posts, which may collect condensation, shall have a 3/16 inch drain hole drilled immediately above the concrete encased area, the base flange, or supporting socket on the side away from the walking area. The bottom of the rail post between the drain hole and the bottom of the post shall be filled with an inert material such as a compressed closed cell neoprene rod.

Bid Set April 2017



G. Safety gates, for guardrail openings, shall be fabricated of matching pipe and rail material and configuration. The gates shall be self-closing gates with approved stop, latch and stainless steel closure spring and hinges.

H. Toeboards shall be provided on all railing adjacent to a drop-in elevation of 4 feet or more. Toeboards are not required on the inclined portion of stairway railings or where concrete or steel curbs, 4 inches or more in height, are present. Toeboards shall be 4-in high channels of the same material as the railing. The channels shall have a minimum thickness of 1/8 inch and have flanges of not less than 3/4 inch nor more than 1-1/2 inches in width. Toeboards shall be positioned with a maximum clearance of 1/4-inch from the floor and fastened to railing posts with 1/4-in stainless steel U-bolts, with J-bolts at corner posts and with clip angles and two 1/4 inch stainless steel expansion bolts at walls.

I. All guardrails shall be properly protected by paper, or by an approved coating or by both against scratching, splashes or mortar, paint, or other defacements during transportation and erection and until adjacent work by other trades has been completed. After protective materials are removed, the surfaces shall be made clean and free from stains, marks, or defects of any kind.

2.6 LADDERS

A. Ladders, ladder accessories and ladder clearances shall conform to the requirements of OSHA.

B. Stainless steel ladders shall be fabricated with 2-1/2 inches by 1/2 inch stainless steel bar side rails spaced a minimum 18 inches apart. Rungs shall be 7/8 inch diameter knurled stainless steel rods spaced maximum 12 inches on center. Ladders shall be fabricated from Type 316 stainless steel. The rungs shall be passed through the side rails, be plug welded on the exterior surface and the weld ground flush and smooth with the exterior surface. Wall support brackets shall be Type 316 stainless steel spaced 5-feet on center with Type 316 stainless steel fasteners. Where possible, the side rails shall be fastened to the floor with 1/2 inch diameter Type 316 stainless steel expansion anchors.

C. Provide a rigid fall prevention system at each ladder more than 20 feet high and as indicated on the Drawings.

1. The system shall consist of stainless steel vertical rigid rail, rail extension, stainless steel mounting hardware and fasteners, two non-corrosive metal sliding fall prevention devices, two stainless steel connecting straps, two full body harnesses with "D" rings, accessories and all other materials required for the complete installation and operation of the fall prevention system in accordance with the manufacturer's recommendations.

2. Provide 36-inch minimum height permanent stainless steel rail extension compatible with the sliding fall prevention device to ensure worker is attached to the fall prevention system while mounting and dismounting from a platform or landing. Ladder extension shall be removable. Provide stainless steel hardware

Bid Set April 2017



and fasteners, accessories, and all other materials required for the complete installation to ladders in accordance with the manufacturer's recommendations.

3. Provide alignment between successive pieces of rail. Provide allowance for expansion and contraction on long runs.

4. In addition to the "D" ring used for attachment to the sliding fall prevention device, the harness shall have at least two "D" rings for the attachment of safety straps and lanyards.

5. The fall prevention system shall be attached to ladders installed under this contract. The sliding fall prevention device shall move freely up and down the rail with the worker in the normal climbing position. The fall prevention system shall stop the fall of a worker independently from offset ladders, platforms or safety cages.

6. Conform to OSHA Regulation 1910.27 for fall prevention system. Rope and cable systems will not be allowed.

7. The fall prevention system shall be Saf-T-Climb by North Safety Products; TS Fall Prevention System by TS Products, Inc.; Glideloc System by Rose Manufacturing Company, or equal.

2.7 MISCELLANEOUS STEEL

A. All miscellaneous metal work shall be formed true to detail, with clean, straight, sharply defined profiles and smooth surfaces of uniform color and texture and free from defects impairing strength or durability. Holes shall be drilled or punched. Edges shall be smooth and without burrs. Fabricate supplementary pieces necessary to complete each item though such pieces are not definitely shown or specified.

B. Connections and accessories shall be of sufficient strength to safely withstand the stresses and strains to which they will be subjected. Exposed joints shall be close fitting and jointed where least conspicuous. Threaded connections shall have the threads concealed where practical. Welded connections shall have continuous welds or intermittent welds as specified or shown. The face of welds shall be dressed flush and smooth. Grind smooth continuous welds that will be exposed. Provide holes for temporary field connections and for attachment of the work of other trades.

C. Miscellaneous steel items shall include: beams, angles, support brackets, base plates for equipment, closure angles, stop plates, and any other miscellaneous steel called for on the Drawings and not otherwise specified.

D. Steel pipe pieces for sleeves, lifting attachments and other functions shall be Schedule 40 pipe unless otherwise shown on the Drawings. Wall and floor sleeves, of steel pipe, shall have welded circumferential steel waterstops at mid-length.

E. All steel finish work shall be thoroughly cleaned, by effective means, of all loose mill scale, rust and foreign matter and shall be given one shop coat of primer compatible with the finish coat after fabrication but before shipment. Paint shall be omitted within

Bid Set April 2017



3-in of proposed field welds. Paint shall be applied to dry surfaces and shall be thoroughly and evenly spread and well worked into joints and other open spaces.

F. Galvanizing, where required, shall be the hot-dip zinc process after fabrication. Coating shall be not less than 2 oz/sq ft of surface.

2.8 MISCELLANEOUS STAINLESS STEEL

A. All miscellaneous metal work shall be formed true to detail, with clean, straight, sharply defined profiles and smooth surfaces of uniform color and texture and free from defects impairing strength or durability. Holes shall be drilled or punched. Edges shall be smooth and without burrs. Fabricate supplementary pieces necessary to complete each item though such pieces are not definitely shown or specified.

B. Connections and accessories shall be of sufficient strength to safely withstand the stresses and strains to which they will be subjected. Exposed joints shall be close fitting and jointed where least conspicuous. Threaded connections shall have the threads concealed where practical. Welded connections shall have continuous welds or intermittent welds as specified or shown. The face of welds shall be dressed flush and smooth. Grind smooth continuous welds that will be exposed. Provide holes for temporary field connections and for attachment of the work of other trades.

C. Miscellaneous stainless steel items shall include: beams, angles, trash racks and any other miscellaneous stainless steel called for on the Drawings and not otherwise specified.

PART 3 EXECUTION

3.1 INSTALLATION

A. Install all items except those to be embedded in concrete which shall be installed under Division 3. Items to be attached to concrete after such work is completed shall be installed in accordance with the details shown.

B. Abrasions in the shop primer shall be touched up immediately after erection. Areas left unprimed for welding shall be painted with primer after welding.

C. Zinc coating which has been burned by welding, abraded, or otherwise damaged shall be cleaned and repaired after installation. The damaged area shall be thoroughly cleaned by wire brushing and all traces of welding flux and loose or cracked zinc coating removed prior to painting. The cleaned area shall be painted with two coats of zinc oxide-zinc dust paint conforming to the requirements of Military Specifications MIL- P-15145. The paint shall be properly compounded with a suitable vehicle in the ratio of one-part zinc oxide to four parts zinc dust by weight.

D. Specialty products shall be installed in accordance with the manufacturer's recommendations.

E. Expansion anchors shall be checked for tightness a minimum of 24 hours after initial installation.

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F. Install adhesive anchor system in strict compliance with the manufacturer's recommendations, including drill bit diameter, surface preparation, temperature, moisture conditions, injection and installation of anchors. Use oil free compressed air to blast out loose particles and dust from the drilled holes. Bolts must be clean and free of dirt, oil, grease, ice or other material which would reduce bond.

G. All railings shall be erected to line and plumb.

H. Headed anchor studs shall be welded in accordance with manufacturer's recommendations.

I. All steel surfaces that come into contact with exposed concrete shall receive a protective coating of an approved heavy bitumastic troweling mastic applied in accordance with the manufacturer's instructions prior to installation.

J. Where aluminum contacts a dissimilar metal, apply a heavy brush coat of zinc- chromate primer followed by two coats of aluminum metal and masonry paint to the dissimilar metal.

END OF SECTION

Bid Set

April 2017

Dampproofing 07110 - 1


SECTION 07110

DAMPPROOFING


A. Furnish all materials, labor, equipment, and incidentals required to perform all the

dampproofing of buried concrete structures as specified herein. 1.2 APPLICATION SCHEDULE

A. All exterior vertical surfaces of buried concrete structures from the footings to the

finished grade elevation shall receive dampproofing as specified herein and as shown on the Drawings.

1.3 RELATED WORK

A. Division 3 - Concrete Work.


A. ASTM International (ASTM):

1. ASTM D1227 – Standard Specification for Emulsified Asphalt Used as a

Protective Coating for Roofing. 1.5 SUBMITTALS

A. Submit to the Engineer for review, in accordance with the provisions of Section

PR-9, shop drawings, working drawings and product data including detailed product information and colors on materials proposed and material installation methods.

B. Submit for review two sets of representative samples of any or all proposed

materials required for the work of this Section as requested by the Engineer. 1.6 QUALITY ASSURANCE

A. The Contractor shall furnish the services of qualified manufacturer’s representatives

at the project site at no additional cost to the Owner at commencement of work under this Section for the dampproofing system and at least one other time during work of this section as determined by the Owner. Representatives shall advise workers in proper installation methods and observe application.

Bid Set

April 2017



B. The factory representatives shall not only meet with the workers responsible for placing the materials but shall also meet with the concrete foremen to review acceptable base surfaces and required detailing for each waterproofing finish. This meeting shall take place before work begins so that required methods and details are established.

PART 2 PRODUCTS

2.1 MATERIALS

A. All materials shall comply with local regulations controlling the use of volatile

organic compounds (VOCs).

B. Dampproofing:

1. Troweled on dampproofing shall be an asphalt emulsion reinforced with fibers conforming to ASTM D1227, Type II, Class 1. The dampproofing shall be Hydrocide 700 by Sonneborn Building Products, Division of ChemRex Inc., Minneapolis, MN; Karnak 920 Asphalt Emulsion by Karnak Corporation, Clark, NJ or equal.

2. Brushed on dampproofing shall be an asphalt emulsion reinforced with

fibers conforming to ASTM D1227, Type II, Class 1. The dampproofing shall be Hydrocide 700B by Sonneborn Building Products, Division of ChemRex Inc., Minneapolis, MN; Karnak 220 Asphalt Emulsion by Karnak Corporation, Clark, NJ or equal.

PART 3 EXECUTION

3.1 INSTALLATION

A. Installation of Dampproofing

1. Surfaces to be treated shall be free from oil and dirt and shall be in the

proper condition as indicated by the Manufacturer prior to the application of the dampproofing material. The concrete shall have been completely cured and the surface shall be dry and free from frost at the time of application.

2. Apply dampproofing to walls after water tightness testing has been

performed.

3. Surfaces to receive troweled on type dampproofing shall receive one heavy coat carefully applied so that "holidays" or air-bubble depressions in the surface are completely filled and a thickness of 1/16-in is obtained from the high points of the surfaces providing a 100 percent coating of the surface. Surfaces to receive brushed on type dampproofing shall receive two coats carefully applied so that no "holidays" are visible. Coating shall extend over exposed top and outside edge of footing. Applying dampproofing shall comply with manufacturer’s application restrictions.

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April 2017



4. Particular care shall be given to the application of dampproofing at all construction joints which are encountered.

5. The number of coats specified is in addition to primer coats as

recommended by the product Manufacturer.

6. Do not place backfill before cure time recommended by Manufacturer and before the wall has been inspected by Engineer. The backfill shall be placed promptly after inspection by Engineer within time limits recommended by Manufacturer.

3.2 CORRECTION OF DEFICIENCIES

A. All deficiencies in work and/or items not meeting specified testing requirements

shall be corrected in order to meet specification requirements at no additional cost to the Owner.

3.3 CLEANUP

A. At all times keep the premises free from accumulation of waste materials and

rubbish. At the completion of the installation remove all tools, scaffolding and surplus materials and remove all of rubbish from and above the area.

B. Remove materials from surfaces where the materials are not required to produce a

clean, neat, workmanlike job.

END OF SECTION

Bid Set

April 2017




Bid Set April 2017

Joint Sealants 07920 - 1


SECTION 07920

JOINT SEALANTS

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required to install joint sealants and related materials in the detention basin expansion joints, as shown on the Draw- ings, and as specified herein.

B. The work includes:

1. Sealing expansion joints in the detention basin or wherever sealant is specified on the drawings with non-sag type sealant.

1.2 RELATED WORK

1.3 SUBMITTALS

A. All submittals shall be in accordance with Section PR-9.

B. Submittals:

1. Proposed Sealant Installer’s Qualifications, in accordance with Paragraph 1.05.C.

2. Sealant Materials provide manufacturer’s technical data describing each product including primer, sealant, and bond breaker tape. Submitted information shall demonstrate compliance with this Section’s requirements.

3. Material Safety Data Sheet (MSDS) for each product to be installed.

4. Installation plan, including equipment to be used for preparation of primer and sealant for installation. Submit installation plan a minimum 45 days prior to date of sealant installation.

C. Samples: Manufacturer's color charts consisting of strips of cured sealants showing the full range of colors available for each product exposed to view.

1.4 JOB CONDIITONS

A. Prior to sealant installation, the expansion joints to be sealed shall be prepared in accordance with Paragraph 3.01.

B. Prior to sealant installation, the Contractor shall be responsible to determine that the concrete substrate moisture content does not conflict with the sealant manufacturer’s recommended substrate condition and installation requirements. The moisture content

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shall not exceed four (4) percent as determined by hand-held moisture detection device, similar to Concrete Moisture Encounter by Tramex Ltd., or approved equal.

C. Sealant Installer should anticipate some additional concrete joint surface preparation work to ensure that the specified product adheres to the joint surfaces in accordance with the requirements of this section.

D. Sealant Installer should anticipate some concrete joint repair work to return the joint to its original profile.


A. Reference Standards:

1. Manufacturers’ specifications and recommendations. The manufacturer of the specified products shall be ISO 9001 certified and have in existence an ongoing quality assurance program that is independently audited on a regular basis.

B. Stipulations:

1. The sealant or caulking material and the corresponding cleaner, joint filler, bond breaker, and primer shall all be products of, or certified as compatible by, the approved manufacturer of the sealant or caulking material.

2. All products shall be suitable and recommended by the manufacturer for the application.

C. Installer Qualifications: The Sealant Installer Company shall have a minimum of 5 years experience in applying similar sealant systems and shall have a successful record of joint and sealant application for minimum of 5 similar projects. Each sealant installer proposed to be assigned to the work of this project shall have a minimum of 5 years experience in sealant application in similar work.

D. Application of Sealants: Install sealants in accordance with the manufacturer’s written instructions. Check expiration date and shelf life of all products before use. Do not use expired products.


A. Deliver all materials in original, unopened containers with the manufacturer’s name, labels, product identification, and batch numbers. Remove any damaged material from the site immediately.

B. Store all material off the ground and protect from rain, freezing or excessive heat until ready for use.

C. Prepare the specified products as recommended by the manufacturer.

1.7 WARRANTY

A. All warranties shall be in accordance with Section 01700.

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PART 2 PRODUCTS

2.1 SEALANT

A. Sealant color: to match existing sealant.

B. All sealant materials shall be as manufactured by SIKA Corporation. Alternative or substitute materials will not be accepted.

2.2 SEALANT APPLICATION AT EXPANSION JOINTS

A. The sealant system shall consist of:

1. Primer: Sikagard 62, two-part epoxy primer on walls of expansion joint

2. Sealant: Sikaflex-2c non-sag elastomeric sealant in the expansion joint

2.3 CONCRETE JOINT PROFILE REPAIR

A. Sealant applicator shall repair joint profile at those locations, determined by the Engi- neer that could compromise bonding of the sealant to the walls of the joint. Damage to original joint profile greater than ¼-inch deep and 1.0-inch long will require repair. Repair shall be made using an epoxy mortar consisting of a mixture of one part Sikadur 35, Hi-Mod LV epoxy and 4 to 5 parts of oven-dried sand. Conform to mixing and application procedures as recommended by the manufacturer. Sand shall be 40-mesh.

2.4 ANCILLARY MATERIALS

A. Joint Fillers: Neoprene, butyl, EPDM, or silicone tubing, non-absorbent to water and gas, capable of remaining resilient at –26 degrees Fahrenheit. Provide products with low compression set and of size and shape to provide a secondary seal, to control sealant depth, and otherwise contribute to optimum sealant performance.

B. Bond Breakers: Polyethylene or plastic tape as recommended by the sealant manufacturer for preventing sealant from adhering to rigid, inflexible joint filler materials or joint surfaces at bottom of joint where such adhesion would result in sealant failure. Provide self-adhesive tape where applicable.

C. Joint Cleaners, Primers, Tooling Liquids, and Clean-up Solvents: Per reference standards.

PART 3 EXECUTION

3.1 EXISTING SEALANT REMOVAL

A. Remove all existing sealant, backer rod, and other residue from all detention basin expansion joints. Protect existing adjoining surfaces from damage including concrete. Leave all surfaces suitable for installation of new sealant. The surface profile of the

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sides of the construction, control, or expansion joint shall conform to a Concrete Sur- face Profile (CSP) 2 or 3, in accordance with ICRI Guideline 03732.

B. Acceptable removal methods include: Cutting out the bulk of the existing sealant with hand-held industrial knives and then cleaning the surfaces of the joint walls with manual abrasion pads or mechanical grinding, taking special care not to damage the profile of the existing expansion joint. Low pressure water blasting is acceptable, so long as the existing joint profile is not damaged. Sand blasting is NOT ACCEPTABLE.

C. Initial test of acceptable removable performance. Engineer will designate two (2) 20- foot long test locations. After the removal of sealant from the test locations, in accordance with the above requirements, Engineer and Approved Sealant Applicator will inspect joints at the test locations to determine if the condition of the joints meets the quality requirements and is suitable for installation of the new sealant. If observed condition does not meet the quality requirements, Contractor will continue removal procedures until the joint surfaces meet the removal quality requirements.

D. After the Engineer’s acceptance of removal quality at the two (2) test locations, Con- tractor may proceed with production removal operations. Owner will provide inspection to determine that removal quality is being met during Contractor’s production operations.

3.2 PREPARATION

A. Refer to Paragraph 3.01 for removal of existing sealant and joint cleaning and preparation requirements.

B. Joints to be filled shall be clean, dry or damp, and free of standing water, weeping beads of water, dust, contaminants, loose abrasive and other foreign materials, suitable to provide a sealant bond, in accordance with these specifications, including the manufacturer’s recommendations. Moisture content shall be as defined above in Paragraph 1.04.B.

C. Repair damaged joint profile in accordance with Paragraph 2.03.A above prior to installing primer.

D. Apply primer to the sides of the joint but not the bottom. Follow manufacturer’s recommendations.

E. Primed surfaces shall be tack free (approximately 4 to 6 hours) but no longer than 24 hours prior to installation of sealant.

3.3 SEALANT APPLICATION IN EXPANSION JOINTS

A. Joint Dimensions

1. Joint dimensions shall be as shown on the contract drawings.

2. Install bond breaker to prevent three-sided adhesion. Refer to the contract drawings for detail. Use adhesive as recommended by sealant manufacturer on bottom side of bond breaker to ensure it does not float during installation of the sealant.

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B. Install sealant in accordance with sealant manufacturer’s recommended installation procedures. Fill joint space completely from bottom to top, without voids, and tool slightly concave; finish uniformly smooth without laps, sags, or depressions.

3.4 INITIAL JOINT MOCK-UP

A. Prior to commencing with production installation of primer, bond breaker and sealant, prepare, prime and install sealant in five, 5-foot long test joints, at locations directed by the Engineer. Perform “pull test” to verify bond adhesion. Provide minimum of 3 days for full cure of sealant, prior to performing the pull tests.

B. Pull Test shall consist of cutting a section of the cured sealant across the sealant and several inches along the joint walls, then pulling the sealant back 180 degrees by hand, stretching it until cohesive sealant failure occurs. Cohesive sealant failure means that the sealant stretches and fails within itself, without pulling away from the primed concrete surface. This is the desired result of the pull test. If however, the sealant fails at the bond line at any of the joint mock-ups, this is an adhesive failure, and cause for rejection of the sealant installation at that mock up. For every failed mock-up, another joint mock-up shall be installed, cured, and pull test performed and approved, before commencing with production installation. After all 5 joint mock-ups have successfully passed their pull tests, as determined by the Engineer; these mock-ups shall become the protocol for the production phase of the sealant installation.

3.5 SEALANT MANUFACTURER’S INSTALLATION INSTRUCTIONS AND

OBSERVATIONS

A. The sealant system manufacturer shall provide a qualified technical representative to witness and instruct Contractor and Sealant Installer staff on the proper installation methods, shall revisit the site at least weekly while sealant work is in progress, and shall furnish written observation report of the installer training, the installation process and the final installation.

3.6 FINISHING

A. Clean all excess sealant materials and other debris, such as dirt, dust and any other foreign materials. Broom clean the reservoir floor and dispose of materials in accordance with the requirements of the Contract Documents.

B. Allow five (5) days cure time for floor joint sealant and encapsulation patches, prior to submergence.

END OF SECTION

Bid Set April 2017




Bid Set April 2017

Surface Preparation and Shop Prime Painting 09901 - 1


SECTION 09901

SURFACE PREPARATION AND SHOP PRIME PAINTING

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required for the surface preparation and application of shop primers on ferrous metals, excluding stainless steels and galvanized steel, as specified herein.

1.2 RELATED WORK

A. Finish painting is included in Section 09902.

1.3 SUBMITTALS

A. Submit, in accordance with Section 01300, shop drawings, manufacturer's specifications and data on the proposed primers and detailed surface preparation, application procedures and dry mil thicknesses.

B. Submit representative physical samples of the proposed primers, if required by the Engineer.


A. The Society for Protective Coatings (SSPC)

1. SSPC-SP 6/NACE No. 3 - Joint Surface Preparation Standard SSPC-SP 6/NACE No. 3: Commercial Blast Cleaning

2. SSPC-SP 10/NACE No. 2 - Joint Surface Preparation Standard SSPC-SP 10/NACE No. 2: Near-White Blast Cleaning.


PART 2 PRODUCTS

2.1 MATERIALS

A. Submerged Surfaces - Shop primer for ferrous metals which will be in contact with water being treated, either submerged, intermittently submerged, located outside or which are subject to splash action or which are specified to be considered submerged service shall be shop primed with the following:

1. Shop Prime Coat: (Zinc Micaceous Iron Oxide Polyurethane Aromatic Shop Primer)

a. TNEMEC: Series 1 Omnithane

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b. Carboline: Carboguard 561

c. Sherwin-Williams Company (The): Corothane I Zinc Primer 1K Mio-Zinc.

d. PPG PMC Durathane MCZ 97-679 Series or PPG PMC Amerlock 400.

e. Or equal.

B. Non-Submerged Surfaces: Shop primer for ferrous metals which will not be in contact with water being treated, not submerged and not subject to splash action shall be shop primed with the following:

1. Shop Prime Coat: (Zinc Micaceous Iron Oxide Polyurethane Aromatic Shop Primer)




d. PPG PMC Durathane MCZ 97-679 Series or PPG PMC Amercoat 68HS

e. Or equal.

C. Submerged Surfaces:

1. Shop Prime Coat for Exterior of Ductile Iron Pipe: (Epoxy, Polyamidoamine Shop Primer)

a. TNEMEC: Series N140 Pota-Pox-Plus


c. Sherwin-Williams Company (The): Macropoxy 846 NSF Winter Grade Epoxy Mill

White

d. PPG PMC Aquapon HB Potable Water Epoxy Coating 95-132 Series or PPG PMC Amerlock 2 Epoxy.

e. Or equal.

2. Shop Prime Coat for Ferrous Metal Surfaces (including Exterior of Steel Pipe): (Zinc Micaceous Iron Oxide Polyurethane Aromatic Shop Primer)




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d. PPG PMC Durathane MCZ 97-679 Series e. Or equal.

D. Non-Primed Surfaces - Gears, bearings surface and other similar surfaces obviously not to be painted shall be given a heavy shop coat of grease or other suitable rust- resistant coating. This coating shall be maintained as necessary to prevent corrosion during all periods of storage and erection and shall be satisfactory to the Engineer up to the time of the final acceptance test.

E. Compatibility of Coating Systems - Shop priming shall be done with primers that are guaranteed by the manufacturer to be compatible with their corresponding primers and finish coats specified in Section 09902for use in the field and which are recommended for use together.

PART 3 EXECUTION

3.1 APPLICATION

A. Surface Preparation and Priming

1. Non-submerged components scheduled for priming, as defined above, shall be blast cleaned in accordance with SSPC-SP 6/NACE No. 3, immediately prior to priming. Submerged components scheduled for priming, as defined above, shall be blast cleaned in accordance with SSPC-SP 10/NACE No. 2, immediately prior to priming. Consult manufacturer regarding required surface profiles.

2. Surfaces shall be dry and free of dust, oil, grease and other foreign material before

priming.

3. Shop prime in accordance with approved manufacturer's recommendations.

B. Non-Primed Surfaces

1. Apply approved coating per manufacturer's recommendations.

3.2 FABRICATED ITEMS

A. All items to be shop primed shall be blast cleaned as specified for applicable service prior to priming. If, in the opinion of the Engineer, any prime coating that has been improperly applied or if material contrary to this Section has been used, that coating shall be removed by abrasive blasting to white metal and reprimed in accordance with this Section.

B. All shop prime coats shall be of the correct materials and applied in accordance with this Section. Remove any prime coats not in accordance with this Section by blast cleaning and apply the specified prime coat at no additional cost to the Owner.

C. Shop primed surfaces shall be cleaned thoroughly and damaged or bare spots prepared as approved and retouched with the specified primer before the application of successive paint coats in the field.

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D. Shop finish coats, if proposed and allowed, shall be equal in appearance and protection quality to a field applied finish coat. If, in the opinion of the Engineer, a shop finish coat system does not give the appearance and protection quality of other work of similar nature, prepare the surfaces and apply the coat or coats of paint as directed by the Engineer to accomplish the desired appearance and protection quality. Submit to the Engineer substantial evidence that the standard finish is compatible with the specified finish coat.

E. Properly protect the shop prime and finish coats against damage from weather or any

other cause.

F. Wherever fabricated equipment is required to be blast cleaned, protect all motors, drives, bearings, gears, etc., from the entry of grit. Equipment found to contain grit shall be promptly and thoroughly cleaned.

END OF SECTION

Bid Set April 2017

Painting 09902 - 1


SECTION 09902

PAINTING

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and install all painting complete as shown on the Drawings and as specified herein.

B. It is the intent of this Section to paint all exposed structural and miscellaneous steel; chemical tanks and systems; mechanical and electrical equipment; sluice gates, operators and posts; conveying systems, pipe, fittings and valves; electrical conduit and appurtenances; new CMU walls; exposed interior ducts; all as specified in the attached painting schedules and all other work obviously required to be painted unless otherwise specified. Minor items not mentioned in the schedule of work shall be included in the work of this Section where they come within the general intent of this Section as stated herein.

C. Paint items so noted in Paragraph 1.01B and in accordance with the Painting Schedule. Provide vinyl film letters and numbers for markings as specified. Items noted in other Specification Sections as having factory finish and other factory finished items are obviously not field painted. The Contractor is responsible for having damaged factory finish painted items repaired or, if so ordered, for replacing items. The various Sections are responsible, as stated in each, for preparation and field touch-up of abrasions, welds and damaged primed areas of primed or galvanized components after erection.

D. The following items will not be painted:

1. Concrete except where specified above and scheduled to be painted and seamless flooring.

2. Stainless steel hatches and frames.

3. Finish hardware.

4. Non-ferrous metals and stainless steel, unless specifically noted otherwise.

5. Factory pre-finished components.

6. Packing glands and other adjustable parts and name plates of mechanical equipment.

7. Maintenance equipment

8. Mechanical, and Electrical equipment which has been finished painted in the factory as specified in Divisions 11, 15 and 16.

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Painting 09902 - 2


1.2 RELATED WORK

A. Valve identification is included in Division15.

B. Shop priming and surface preparation of equipment and piping (except copper piping) are specified in Section 09901 and included in the respective Section with the item to be primed.

C. Shop priming of metal substrates with primers is included in Division 5.

1.3 SUBMITTALS

A. Submit the following in accordance with Section 01300.

B. Product Data: For each type of product indicated.

C. Samples: Submit the following for each type of coating system and in each color and gloss of finish coat indicated.

1. Color cards for initial color selections.

2. Three sets of 8-in by 8-in samples, on 1/4-in hardboard, of all colors required for all types of paint. Resubmit until approved.

D. Product List: For each product indicated. Cross-reference products to coating system and

locations of application areas. Use same designations indicated on Drawings and in schedules.

E. LEED Submittals:

1. Product Data for Credit EQ 4.2: For coatings, including printed statement of VOC content and chemical components.


A. Steel Structures Painting Council (SSPC)

1. SSPC SP-1 - Surface Preparation Specification No. 1 Solvent Cleaning.

2. SSPC SP-2 - Surface Preparation Specification No. 2 Hand Tool Cleaning.



A. Store materials not in use in tightly covered containers in well-ventilated areas with ambient temperatures continuously maintained at not less than 45 deg F.

1. Maintain containers in clean condition, free of foreign materials and residue.

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Painting 09902 - 3


2. Remove rags and waste from storage areas daily.

1.6 PROJECT CONDITIONS

A. Apply coatings only when temperature of surfaces to be coated and surrounding air temperatures are between 50 and 95 deg F.

B. Do not apply coatings in snow, rain, fog, or mist; when relative humidity exceeds 85 percent; at temperatures, less than 5 degrees F above the dew point; or to damp or wet surfaces.

1.7 EXTRA MATERIALS

A. Furnish extra materials described below that are from same production run (batch mix) as materials applied and that are packaged for storage and identified with labels describing contents.

1. Quantity: Furnish an additional 5percent, but not less than 1 gal. of each material and color applied.

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Provide products by one of the following:

1. Tnemec, Inc.(TN);

2. The Sherwin Williams Company (SW)

3. PPG Architectural Finishes, Inc. (PPG)

4. PPG Architectural Finishes, Inc. Ameron (AME)

5. Or equal. 2.2 MATERIALS

A. Material Compatibility:

1. Provide materials for use within each coating system that are compatible with one another and substrates indicated, under conditions of service and application as demonstrated by manufacturer, based on testing and field experience.

2. Provide products of same manufacturer for each coat in a coating system.

B. All painting materials shall be delivered to the work site in unbroken packages, bearing the manufacturer's brand and name. They shall be used without adulteration and mixed, thinned and applied in strict accordance with manufacturer's directions for the applicable materials and surface and with the Engineer's approval before using.

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Painting 09902 - 4


C. Shop priming shall be done with primers that are guaranteed by the manufacturer to be compatible with the finish paints to be used. Refer to Section 09901for special primers.

D. Work areas will be designated by the Engineer for storage and mixing of all painting materials. Materials shall be in full compliance with the requirements of pertinent codes and fire regulations. Proper containers outside of the buildings shall be provided and used for painting wastes and no plumbing fixture shall be used for this purpose.

E. Colors: As selected by Owner from manufacturer's full range.

2.3 COLOR CODING FOR PIPES

A. The color code establishes, defines and assigns a definite color for each pipe system. All elements which are an integral part of the system, that is originating from, shall be painted between and up to but not including the fixed flanges nor the flexible conduit connections on the equipment. Valves and fittings shall be painted in the color of the main body of the pipe.

B. All pipes shall be painted with final coat color selected by the Owner and shall be treated as an integral part of the Contract.

C. All hanger saddles and pipe support floor stands shall be painted the same color and with the same paint as the pipe it supports. Hanger rods and hanger rod connections to building structure shall be painted to match the color of the wall or ceiling to which it is attached.

2.4 LETTERING OF TITLES

A. Refer to Section 15120 for requirements. 2.5 TITLES FOR EQUIPMENT

A. Titles shall be provided in vinyl film as specified above on all above grade equipment using 1-in high Optima Bold upper case, Grid 2 spacing, white or black in color as approved depending on substrate. Use titles shown on mechanical drawings for bidding purposes. Titles shall be mounted at eye level on machines where possible or at the upper most broad vertical surface of low equipment. Where more than one piece of the equipment item to be titled exists, the items shall be numbered consecutively as indicated on the mechanical drawings or as directed by the Engineer; for example, Pump No. 1, Pump No. 2, etc. Titles shall be composed in more than one line if required and justified on the left-hand side as approved.

2.6 TESTING EQUIPMENT

A. Furnish to the Engineer for use on the Project for paint inspection, wet and dry film thickness gauges and all other equipment required by the Owner for inspection.

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Painting 09902 - 5


PART 3 EXECUTION

3.1 EXAMINATION

A. Examine substrates and conditions, with Applicator present, for compliance with requirements for maximum moisture content and other conditions affecting performance of work.

1. Maximum Moisture Content of Substrates: When measured with an electronic moisture meter as follows:

a. Concrete: 12 percent.

b. Masonry (Clay and CMU): 12 percent.

c. Wood: 15 percent.

2. Verify compatibility with and suitability of substrates, including compatibility with existing finishes or primers.

3. Begin coating application only after unsatisfactory conditions have been corrected and surfaces are dry.

4. Coating application indicates acceptance of surfaces and conditions.

3.2 PREPARATION

A. All surfaces to be painted shall be prepared as specified herein and shall be dry and clean before painting. Special care shall be given to thoroughly clean interior concrete and CMU surfaces to receive polyamide cured epoxy paint of all marks before application of finish.

B. All metal welds, blisters, etc., shall be ground and sanded smooth. All pits and dents shall be filled and all imperfections shall be corrected so as to provide a smooth surface for painting. All rust, loose scale, oil, tar and asphalt bearing coatings, grease and dirt shall be removed by use of approved solvents, wire brushing, grinding or sanding.

C. Concrete surfaces shall have been finished as specified in Section 03350. Report unsatisfactory surfaces to the Engineer. Concrete shall be left for one-month minimum before painting and shall be free of dust, oil, curing compounds and other foreign matter.

D. Concrete masonry unit surfaces shall be smooth and cleaned of all dust, loose mortar and other foreign matter.

E. All PVC pipe and other plastic matrix surfaces to be painted shall be sanded to an

approved profile and cleaned of residue before painting.

F. All PVC pipe and other plastic matrix surfaces to be painted shall be lightly sanded and cleaned of residue before painting.

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Painting 09902 - 6


G. Galvanized, aluminum, and copper surfaces shall have all oxidation and foreign material removed before painting by SSPC SP-1, using an approved V.O.C. compliant method. Galvanized and, when ordered, the other metal surfaces specified above shall be hand tool cleaned to SSPC SP-2 standards to provide a uniform 1 mil surface profile.

H. Existing Surfaces to be Repainted

1. Existing masonry, steel and other previously field painted surfaces so noted or as provided in Paragraph 1.01B shall be repainted.

2. Preparation shall be in general as specified above for new surfaces except that all loose paint shall be removed and all edges of existing paint shall be feathered to ensure a smooth surface.

3. Paint removal, capture of its residue, and its disposal shall be handled in accordance with all laws and regulations concerning disposal of hazardous materials.

4. Primer (spot) and paint used for a particular surface shall, in general, be as scheduled for that type of new surface. Provide a specified organic zinc-rich (min. 83 percent zinc in dried film) primer as specified. Confirm with the paint manufacturer that the paint proposed for a particular repaint condition will be compatible with the existing painted surface. Perform adhesion and compatibility tests on existing substrates as ordered and required. Repainted areas shall be covered by the same guaranty specified for remainder of Project.

3.3 WORKMANSHIP

A. General

1. At the request of the Owner or Engineer, sample areas of the finished work prepared in strict accordance with this Section shall be furnished and all painting shall be equal in quality to the approved sample areas. Finished areas shall be adequate for the purpose of determining the quality of workmanship. Experimentation with factory or paint manufacturer's warehouse mixed colors shall be furnished to the satisfaction of the Engineer where standard chart colors are not satisfactory.

2. Protection of furniture and other movable objects, equipment, fittings and accessories shall be provided throughout the painting operation. Canopies of lighting fixtures shall be loosened and removed from contact with surface, covered and protected and reset upon completion. Remove all electric plates, surface hardware, etc., before painting, protect and replace when completed. Mask all machinery name plates and all machined parts not receiving a paint finish. Dripped or spattered paint shall be promptly removed. Lay drop cloths in all areas where painting is being done to adequately protect flooring and other work from all damage during the operation and until the finished job is accepted.

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Painting 09902 - 7


3. On metal surfaces apply each coat of paint at the rate specified by the manufacturer to achieve the minimum dry mil thickness required. If material has thickened or must be diluted for application by spray gun, the coating shall be built up to the same film thickness achieved with undiluted material. One gallon of paint as originally furnished by the manufacturer shall not cover a greater area when applied by spray gun than when applied unthinned by brush. Deficiencies in film thickness shall be corrected by the application of an additional coat(s). On masonry, application rates will vary according to surface texture; however, in no case shall the manufacturer's stated coverage rate be exceeded. On porous surfaces, it shall be the painter's responsibility to achieve a protective and decorative finish either by decreasing the coverage rate or by applying additional coats of paint.

B. Field Priming

1. Steel members, metal castings, mechanical and electrical equipment and other metals which are shop primed before delivery at the site will not require a prime coat on the job. All piping and other bare metals to be painted shall receive one coat of primer before exposure to the weather, and this prime coat shall be the first coat as specified in the painting schedule. Surface preparation of bare metal shall be the responsibility of the Contractor.

2. Equipment which is specified to receive a baked-on enamel finish or other factory finish shall not be field painted unless the finish has been damaged in transit or during installation. Surfaces that have been shop painted and have been damaged, or where the shop coat or coats of paint have deteriorated, shall be properly cleaned and retouched before any successive painting is done on them in the field. All such field painting shall match as nearly as possible the original finish. Preparation and painting shall be provided by the Contractor.

3. Equipment shipped with a protective shop painting coat or coats shall be touched up to the satisfaction of the Engineer with primers as recommended by the manufacturer of the finish paint. Preparation and painting shall be provided by the Contractor.

C. Field Painting

1. All painting at the site shall be under the strict inspection of the Engineer. Only skilled painters and, where dictated by special conditions or systems and so ordered, specialist painters shall be used on the work.

2. All paint shall be at room temperature before applying, and no painting shall be done when the temperature is below 60 degrees F, in dust-laden air, when rain or snow is falling, or until all traces of moisture have completely disappeared from the surface to be painted.

3. Successive coats of paint shall be different shades (from paint manufacturer's stock or shop mixed paint) of the required colors so as to make each coat easily distinguishable from each other with the final undercoat the approximate shade of the finished coat to ensure no show-through as approved.

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Painting 09902 - 8


4. Finish surfaces shall not show brush marks or other irregularities. Undercoats shall be thoroughly and uniformly sanded with the type paper appropriate for the undercoats to remove defects and provide a smooth even surface. Top and bottom edges of doors shall be painted.

5. Painting shall be continuous and shall be accomplished in an orderly manner so as to

facilitate inspection. Materials subject to weather shall be primed coated as quickly as possible. Surfaces of exposed members that will be inaccessible after erection shall be cleaned and painted before erection.

6. All painting shall be performed by approved methods with number of coats modified as required to obtain the total dry film thickness specified. Spray painting shall be performed specifically by methods submitted and as approved by the Engineer.

7. All surfaces to be painted as well as the atmosphere in which painting is to be done shall be kept warm and dry by heating and ventilation, if necessary, until each coat of paint has hardened. Any defective paint shall be scraped off and repainted in accordance with the Engineer's directions.

8. Before final acceptance of the work, all damaged surfaces of paint shall be cleaned and repainted as directed by the Engineer.

9. Only the aluminum work noted on the Drawings or in the Painting Schedule shall be field painted.

3.4 FIELD QUALITY CONTROL

A. Owner reserves the right to invoke the following procedure at any time and as often as Owner deems necessary during the period when coatings are being applied:

1. Owner will engage the services of a qualified testing agency to sample coating material being used. Samples of material delivered to Project site will be taken, identified, sealed, and certified in presence of Contractor.

2. Testing agency will perform tests for compliance with specified requirements.

3. Owner may direct Contractor to stop applying coatings if test results show materials being used do not comply with specified requirements. Contractor shall remove noncomplying coating materials from Project site, pay for testing, and recoat surfaces coated with rejected materials. Contractor will be required to remove rejected materials from previously coated surfaces if, on recoating with complying materials, the two coatings are incompatible.

3.5 CLEANING AND PROTECTION

A. At end of each workday, remove rubbish, empty cans, rags, and other discarded materials from Project site.

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Painting 09902 - 9


B. After completing coating application, clean spattered surfaces. Remove spattered coatings by washing, scraping, or other methods. Do not scratch or damage adjacent finished surfaces.

C. Protect work of other trades against damage from coating operation. Correct damage by cleaning, repairing, replacing, and recoating, as approved by Engineer, and leave in an undamaged condition.

D. At completion of construction activities of other trades, touch up and restore damaged or defaced coated surfaces.

3.6 PAINTING SCHEDULE

A. All colors will be selected by the Owner.

B. The following types of paints by PPG Protective & Marine Coatings, (PPG PMC); Tnemec Co. (TN) and The Sherwin Williams Company (SW) have been used as a basis for the paint schedule:

1. Epoxy:

a. TN: Hi-build Epoxoline II (Series N69)

b. SW:Macropoxy 646

c. PPG PMC: Pitt-Guard 97-145 Series Epoxy Mastic

d. AME: Amerlock 2/400 Series Epoxy

e. Or equal.

2. Waterborne Cementitious Acrylic:

a. TN: Envirofil (No. 130-6602 off-white color)

b. SW:Cement-Plex 875

c. PPG: Cementitious Waterproofing Block Filler 95-217 Series

d. AME: Amerlock 400 BF Epoxy Block Filler

e. Or equal.

3. High-Build Acrylic Polyurethane Enamel:

a. TN: Endura-Shield III - semi-gloss (Series V73)

b. SW:Acrolon 218 HS

c. PPG: Pitthane HB Semigloss Urethane 95-8800 Series

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d. AME: Amercoat 450H SG Polyurethane

e. Or equal.

4. High Heat Silicone Aluminum (to 600 degrees F)

a. TN: Silicone Aluminum (No. 39-661)

b. SW:Kem Hi-Temp No.850

c. PPG: Speedhide 6-220 Series Silicone Aluminum Coating

d. AME: Amercoat 878 Silicone Aluminum Coating

e. Or equal.

5. Tie Coat, Low VOC, Epoxy:

a. TN: FC Typoxy (Series V27)

b. SW:Macropoxy HS

c. PPG: Pitt-Guard Epoxy Mastic 95-245 Series

d. AME: Amercoat 385 Multi-purpose Epoxy

e. Or equal.

6. Acrylic Latex Emulsion, Eggshell Finish:

a. TN: Tneme-Cryl (Series 6)

b. SW:DTM Primer Finish

c. PPG: Pitt-tech Plus 90-1110 Series Satin DTM Acrylic

d. AME: Amercoat 220 Waterborne Acrylic

e. Or equal.

7. Vinyl Acrylic Surface Sealer:

a. TN: PVA Sealer (No. 51-792)

b. SW:Prep-Rite 200 Primer

c. PPG: Speedhide 6-2 Vinyl Acrylic Drywall Primer

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Painting 09902 - 11

d. AME: Amercoat 148 Acrylic Primer

e. Or equal.


C. The following surfaces shall have the types of paint scheduled below applied at the dry film thickness (DFT) in mils per coat noted:

1. Exterior non-submerged ferrous metals (except first coat-hollow metal-pressed metal work).

a. First Coat: On properly prepared unprimed metal or for touch-up

1) TN: No. N69 (white in color) (3.0-4.0 DFT) 2) SW: Macropoxy 646 (5.0-10.0 DFT) 3) PPG: Pitt-Guard 97-145 Series Epoxy Mastic 4) AME: Amerlock 2/400 Series Epoxy 5) Or equal.

b. Second Coat:

1) TN: Series N69 (4.0 DFT) 2) SW: Acrolon 218 HS (3.0-6.0 DFT) 3) PPG: Pitt-Guard 97-145 Series Epoxy Mastic 4) AME: Amerlock 2/400 Series Epoxy 5) Or equal.

c. Third Coat:

1) TN: Series V73 (3.0 DFT) 2) SW: Acrolon 218 HS (3.0-6.0 DFT) 3) PPG: Pitthane HB Semigloss Urethane 95-8800 Series 4) AME: Amercoat 450H SG Polyurethane 5) Or equal.

2. Interior non-submerged concrete scheduled for painting.

a. First and Second Coats: 1) TN: Series N69 (4.0-5.0 DFT) 2) SW: Macropoxy 646 (5.0-10.0 DFT) 3) PPG: Pitt-Guard 97-145 Series Epoxy Mastic 4) AME: Amerlock 2/400 Series Epoxy 5) Or equal.

3. Interior concrete masonry units

a. First Coat:

1) TN: No. 130-6602 (80 sq ft./gal minimum scrub-in to fill voids as approved)

2) SW: Cement-Plex 875 (50-100 sq. ft./gal.) 3) PPG: Cementitious Waterproofing Block Filler 95-217 Series 4) AME: Amerlock 400 BF Epoxy Block Filler 5) Or equal.

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Painting 09902 - 12


b. Second and Third Coats: 1) TN: Series N69 (5.0 DFT) 2) SW: Macropoxy 646 (5.0-10.0 DFT) 3) PPG: Pitt-Guard 97-145 Series Epoxy Mastic 4) AME: Amerlock 2/400 Series Epoxy 5) Or equal.

4. Interior non-submerged ferrous metals (except first coat of previously painted metal work), on properly prepared unprimed metal or for touch-up.

a. First Coat:

1) TN: No. N69 (white in color) (3.0-4.0 DFT) 2) SW: Macropoxy 646 (5.0-10.0 DFT) 3) PPG: Pitt-Guard 97-145 Series Epoxy Mastic 4) AME: Amerlock 2/400 Series Epoxy 5) Or equal.

b. Second and Third Coats:

1) TN: Series N69 (3.0-4.0 DFT) 2) SW: Macropoxy 646 (5.0-10.0 DFT) 3) PPG: Pitt-Guard 97-145 Series Epoxy Mastic 4) PPG: Amerlock 2/400 Series Epoxy 5) Or equal.

5. Submerged ferrous metals and ferrous metals subject to submersion or splashing. Surface shall be lightly sanded or abraded before application of first field coat.

a. First and Second Coats:

1) TN: Series N69 (6.0 DFT) 2) SW: Macropoxy 646 (5.0-10.0 DFT) 3) PPG: Pitt-Guard 97-145 Series Epoxy Mastic 4) PPG: Amerlock 2/400 Series Epoxy 5) Or equal.

6. Plastic piping and, where scheduled to be painted, plastic components


1) TN: Series N69 (3.0 DFT) 2) SW: Macropoxy 646 (5.0-10.0 DFT) 3) PPG: Pitt-Guard 97-145 Series Epoxy Mastic 4) AME: Amerlock 2/400 Series Epoxy 5) Or equal.

7. Previously painted existing concrete/CMU scheduled for painting:

a. First Coat: 1) TN: Series 113 (3.0-4.0 DFT) 2) SW: Epo-Plex Multi-Mil (4.0-6.0 DFT) 3) PPG: Aquapon WB Epoxy 98-1 Series

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Painting 09902 - 13


4) AME: Amercoat 335 WB Epoxy 5) Or equal.

b. Second Coat:

1) TN: Series 297 (2.0-2.5 DFT) 2) SW: Epo-Plex Multi-Mil (4.0-6.0 DFT) 3) PPG: Aquapon WB Epoxy 98-1 Series 4) AME: Amercoat 335 WB Epoxy 5) Or equal.

8. Existing precast concrete plank ceilings scheduled to be painted.


1) TN: Series 113 (3.0-4.0 DFT) 2) SW: Epo-Plex Multi-Mil (4.0-6.0 DFT) 3) PPG: Aquapon WB Epoxy 98-1 Series 4) AME: Amercoat 335 WB Epoxy 5) Or equal.

9. Aluminum designated to be painted. (Mechanically abrade surfaces to a uniform profile of 1 to 2 mils and clean completely.)

a. First and Second Coats: (Interior)

1) TN: Series N69 (3.0 DFT) 2) SW: Macropoxy 646 (5.0-10.0 DFT) 3) PPG: Pitt-Guard 97-145 Series Epoxy Mastic 4) AME: Amerlock 2/400 Series Epoxy 5) Or equal.

b. First Coat: (Exterior)

1) TN: Series N69 (4.0 DFT), 1 coat Series V73 (3.0 DFT) 2) SW: Macropoxy 646 (5.0-10.0 DFT), Acrolon 218 HS (3.0-6.0 DFT) 3) PPG: Pitt-Guard 97-145 Series Epoxy Mastic 4) AME: Amerlock 2/400 Series Epoxy 5) Or equal.

10. Copper piping

a. First and Second Coats: 1) TN: Series N69 (3.0 DFT) 2) SW: Macropoxy 646 (5.0-10.0 DFT) 3) PPG: Pitt-Guard 97-145 Series Epoxy Mastic 4) AME: Amerlock 2/400 Series Epoxy 5) Or equal.

11. Hot ferrous metal surfaces


1) TN: Series 39-661 (1.5 DFT) 2) SW: Kem Hi-Temp 850 (Primer 1.1 DFT / Topcoat 1.0-1.2 DFT)

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3) PPG: Speedhide 6-220 Series Silicone Aluminum Coating 4) AME: Amercoat 878 Silicone Aluminum Coating 5) Or equal.

12. Previously painted metal surfaces - First coat on substrates prepared as approved and replacing first coat of above-specified systems. Complete painting with remainder of specified system for each type of substrate.

a. First Coat:

1) TN: FC Typoxy Series V27 (5 DFT) 2) SW: Macropoxy HS (3.0-6.0 DFT) 3) PPG: Pitt-Guard 97-145 Series Epoxy Mastic 4) AME: Amerlock 2/400 Series Epoxy 5) Or equal.

13. Exterior galvanized steel surfaces, if coating identified on the Drawings. (Mechanically abrade surfaces to a uniform profile of 1 to 2 mils and clean completely.)

a. First Coat:

1) TN: Series V27 (3.0 to 4.0 DFT) 2) SW: Macropoxy 646 (5.0-10.0 DFT) 3) PPG: Pitt-Guard Epoxy Mastic 95-245 Series 4) AME: Amercoat 385 Multi-purpose Epoxy 5) Or equal.

b. Second Coat:

1) TN: Series V73 (2.5 to 3.5 DFT) 2) SW: Acrolon 218 HS (3.0-6.0 DFT) 3) PPG: Pitthane HB Semigloss Urethane 95-8800 Series 4) AME: Amercoat 450H SG Polyurethane 5) Or equal.

END OF SECTION

Bid Set April 2017

Submersible Solids Handling Pumps 11306-1


SECTION 11306

SUBMERSIBLE SOLIDS HANDLING PUMPS

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and install, place in operation and field test three submersible solids handling pumps as shown on the Drawings and specified herein. The equipment to be furnished and installed shall be as shown on the Drawings and shall include pumps, motors, guide rails, pump/motor protection system, and appurtenances, all tested and ready for operation.

B. These Specifications are intended to give a general description of what is required, but do not cover all details which will vary in accordance with the requirements of the equipment as offered. It is, however, intended to cover the furnishing, factory testing, delivery and complete installation and field testing of all materials, equipment and appurtenances for the complete pumping units as herein specified, whether specifically mentioned in these Specifications or not.

C. Pump motors, cables and appurtenances shall be rated for operation in a Class I Division 1, Group D hazardous environment.

D. The pump manufacturer shall coordinate the design of the pump and motor with the soft starters specified in Division 16.

1.2 RELATED WORK

A. Submittals are included in Section 01300.

B. Operation and maintenance is included in Section 01730.

C. Warranties are included in Section 01740.

D. Concrete work and the installation of anchor bolts are included in Division 3; however, anchor bolts for these pumps shall be as recommended and furnished by the pump manufacturer under this Section.

E. Instrumentation work is included in Division 13.

F. Pump operation and control shall be as described in Section 13305.

G. Valves, mechanical piping and appurtenances and pipe hangers and supports are included in Division 15.

H. Electrical work is included in Division 16.

Bid Set April 2017




A. Design, manufacturing and assembly of elements of the equipment herein specified shall be in accordance with, but not limited to, published standards of the following, where applicable:

1. American Gear Manufacturers Association (AGMA)

2. American Institute of Steel Construction (AISC)

3. American Iron and Steel Institute (AISI)

4. American Petroleum Institute (API)

5. American Society of Mechanical Engineers (ASME)

6. American National Standards Institute (ANSI)

7. American Society for Testing Materials (ASTM)

8. American Welding Society (AWS)

9. American Bearing Manufacturers Association (ABMA)

10. Hydraulic Institute Standards

11. Institute of Electrical and Electronics Engineers (IEEE)

12. National Electric Code (NEC)

13. National Electrical Manufacturers Association (NEMA)

14. Occupational Safety and Health Administration (OSHA)

15. Steel Structures Painting Council (SSPC)

16. Underwriters Laboratories, Inc. (UL)

17. Factory Mutual (FM)



A. The system will pump stormwater. The equipment to be furnished under this Section shall include three submersible solids handling pumps, motors, and accessories such as guide rails, all as specified herein and as shown on the Drawings. Refer to section 13305 for system description and control narratives. Contractor shall coordinate and be fully responsible for proper operation and compatibility between items in this scope of work and items in Division 13 scope.

Bid Set April 2017



1.5 QUALIFICATIONS

A. To assure unity of responsibility, the pumps, motors, guide rails and other auxiliary equipment, and materials specified in this Section shall be furnished and coordinated by the pump manufacturer (Manufacturer) who shall assume responsibility for the satisfactory operation of the entire pumping system including pumps, motors, and accessories.

B. The pumps and other equipment covered by this Specification shall be standard production units of the manufacturers, currently available and listed in the respective manufacturer's catalog. The pumps furnished shall be in accordance with the Hydraulic Institute Standards and shall be designed, constructed and installed in accordance with the best practice and methods, and shall operate satisfactorily when installed.

C. The Manufacturer or its representative shall have an authorized warranty center within a 300-mile radius of the job site, fully staffed with factory trained mechanics, and equipped with a stock of strategic spare parts for each model of pump furnished under this Contract. The service facility and strategic spare parts shall be established prior to delivery of equipment for this project.

D. All equipment furnished under this Specification shall be new and unused, shall be the standard product of manufacturers having a successful record of manufacturing and servicing similar equipment and systems to that specified herein for a minimum of five years.

E. The pumping equipment shall be furnished complete with accessories required and shall meet the detailed requirements of the Specifications.

F. Prior to manufacture, a submittal shall be forwarded to the Engineer indicating that the required vibration analyses outlined in this Part have been made and that the specified limitations will be met. For the dynamic vibration analysis described, minimum and maximum operating speeds will be in accordance with the operating speeds required to satisfy the conditions of operation specified in Paragraph 2.02. The dynamic vibration analysis presented in the following paragraph shall be performed by Mechanical Solutions Inc. (MSI) of Whippany, NJ, Engineering Dynamics Inc. (EDI) of San Antonio, TX or alternatively by the Manufacturer if Manufacturer’s demonstrated successful vibration analysis experience with proposed personnel involved in at least 20 projects similar in scope is acceptable to the Engineer and analysis is in accordance with the specified requirements.

1. Lateral rotodynamic analysis - The lateral rotodynamic analysis shall identify and predict that the first lateral critical speed shall be at least 20 percent above or below the pump full load speed and vane pass frequency. Any pump component excited resonant frequency shall be no closer than plus or minus 20 percent of the natural frequency of any part of the installed assembled pumping unit.

2. The pumps shall operate throughout the entire operating range with the maximum vibration velocity in inches per second RMS, measured in the field, shall conform to the requirements of ANSI/HI 11.6.

Bid Set April 2017



1.6 SUBMITTALS

A. Copies of all materials required to establish compliance with the Specifications shall be submitted in accordance with the provisions of the General Conditions and Section 01300. Submittals shall include at least the following:

1. Shop and erection drawings showing all important details of construction, dimensions and anchor bolt installation requirements. Submittal shall demonstrate that hatch clear opening is sufficient for the pump supplied.

2. Descriptive literature, bulletins, and/or catalogs of the equipment. Sufficient data shall be submitted to document previous production of each pump model proposed for use on this Contract.

3. Data on the characteristics and performance of each pump. Data shall include guaranteed performance curves to ANSI/HI 11.6 acceptance grade 1U for all specified points, based on actual factory tests of similar units, which show that they meet the specified requirements for head, flow rate, efficiency, NPSH3, submergence and horsepower. Curves shall be submitted on 8-1/2- by 11-inch sheets, at as large a scale as is practical. Curves shall be plotted from zero flow at shut off head to pump flow rate at minimum specified total head (TH). The POR and AOR (refer to ANSI/HI 9.6.3) shall be clearly shown on the curves. This information shall be prepared specifically for the pump proposed. Catalog sheets showing a family of curves will not be acceptable.

4. The total weight of the equipment including the weight of the single largest item.

5. Complete wiring diagrams and schematics of all power and control systems showing wiring requirements between all system components, motors, sensors, control panels and related systems.

6. A complete total bill of materials of all equipment.

7. A list of the manufacturer's recommended spare parts to be supplied, with the manufacturer's current price for each item. Include gaskets, seals, etc. on the list. List bearings by the bearing manufacturer's numbers only.

8. All submittal data required by the General Conditions.

9. Complete motor data, including, but not limited to:

a. Type of enclosure design

b. Rated horsepower

c. Rated voltage

d. FLA

e. Starting current

Bid Set April 2017



f. LRA

g. LR KVA

h. NEMA starting code letter and insulation code letter

i. RPM

j. Input power in kW at nameplate rating

k. Starting calculations

l. Cable size

m. Efficiency at 50 percent, 75 percent and 100 percent load, and power factor at 50 percent, 75 percent, and 100 percent load

n. Winding temperature rise

o. Vibration design limits

p. Speed torque curves

q. Recommended trip and alarm settings for temperature and vibration

protective devices

r. Power and control cable size and materials of construction , details of cable sealing method, description and type of motor thermal protection, description of insulation system and service factor.

10. Submit a certified statement from the motor manufacturer that the motors are capable of a minimum of 10 starts per hour and continuous operation on the power supply from the soft starters to be furnished without affecting their design life for bearings and windings.

11. Certified agreement to the conditions of the warranty.

12. Submit description of factory test plan including test procedures and equipment.

13. Submit description of field test plan including test procedures and equipment.

14. Submit for approval results of factory testing and field testing.

15. Critical speed analyses report including the specified Campbell diagrams and a statement of guarantee that the critical speed analyses as required in Paragraph 1.05F. of this Section have been completed and that the specified limitations will be met.

B. In the event that the equipment offered does not conform with all of the detailed requirements of the Specifications, describe completely all nonconforming aspects.

Bid Set April 2017



Failure to describe any and all deviations from the specifications will be cause for rejection.

1.7 OPERATING INSTRUCTIONS

A. Operating and Maintenance Manuals shall be furnished. The manuals shall be prepared specifically for equipment furnished and installed on this Contract and shall include all required cuts, drawings, equipment lists, descriptions, etc. that are required to instruct operating and maintenance personnel unfamiliar with such equipment. The number and special requirements shall be as specified in the Section 01730.

B. The Contractor shall include in his bid price the services of a pump factory representative for two eight hour sessions. The first eight hour period shall be to inspect for proper installation. The second eight hour period shall be to instruct the Owner’s personnel for proper operation and maintenance of the pumps.

C. The Manufacturer shall provide detailed manuals to supplement the training courses. The manuals shall include specific details of equipment supplied and operations specific to the project.

D. The Manufacturer shall make use of teaching aids, manuals, slide/video presentations, etc. After the training services, such materials shall be delivered to Owner.

1.8 TOOLS AND SPARE PARTS

A. The Manufacturer shall furnish a complete list of recommended spare parts, gaskets, lubricants and sealants and heat transfer medium necessary for the first five years operation of each pumping system.

1.9 PRODUCT HANDLING

A. All equipment and parts shall be properly protected so that no damage or deterioration will occur during a prolonged delay from the time of fabrication, including storage in accordance with Manufacturer’s requirements until final delivery to the job site.

B. Factory assembled parts and components shall not be dismantled for shipment unless permission is received in writing from the Engineer.

C. Finished surfaces of all exposed pump openings shall be protected by wooden blanks, strongly built and securely bolted thereto or by other approved means.

D. Finished iron or steel surfaces not painted shall be properly protected to prevent rust and corrosion.

E. After hydrostatic or other tests, all entrapped water shall be drained prior to shipment

and proper care shall be taken to protect parts from the entrance of water during shipment, storage and handling.

Bid Set April 2017



F. Each box or package shall be properly marked to show its net weight in addition to its contents.

1.10 WARRANTY

A. All equipment supplied under this section shall be warranted for a period outlined in Divisions 1 and 0 by the Contractor and the Manufacturer. Warranty period shall commence on the date of Owner acceptance, as outlined in Division 1 and in Division 0.

B. The equipment shall be warranted to be free from defects in workmanship, design and materials. If any part of the equipment should fail during the warranty period, it shall be replaced in the machine(s) and the unit(s) restored to service at no expense to the Owner.

C. The Manufacturer’s warranty period shall run concurrently with the Contractor’s warranty period. No exception to this provision shall be allowed.

D. Refer to Section 01740 for additional warranty requirements.

PART 2 PRODUCTS

2.1 GENERAL

A. The pumping units required under this Section shall be complete including pumps and motors with proper alignment and balancing of the individual units. All parts shall be so designed and proportioned as to have liberal strength, stability, and stiffness and to be especially adapted for the work to be done. Ample room shall be provided for inspection, repairs, and adjustments.

B. Each base elbow (discharge connection) for each pump shall be designed to be rigidly and accurately anchored into position. All necessary anchor bolts, plates, nuts, and washers shall be furnished by Manufacturer and installed by the Contractor in strict accordance with the Manufacturer’s recommendations. Manufacturer shall retain the services of professional engineer licensed in California to evaluate the pump anchorage to structure. Submit signed and sealed certification that anchorage is suitable for the conditions of service and seismic design criteria.

C. Stainless steel nameplates giving the name of the manufacturer, the rated flow rate, head, speed, and all other pertinent data shall be permanently attached to each pump and/or motor. Additional stainless steel nameplates shall be provided to be installed by the Contractor on the electrical enclosure or other above grade location as instructed by the Engineer such that the pumps do not need to be removed to gather the information.

D. The pumps shall be totally submersible, solids handling, rotodynamic pumps with submersible close coupled motors designed to pump stormwater. The design shall be such that the pumping units shall be automatically connected to the discharge piping when lowered into place on the discharge connection, providing a water tight seal. The pumps shall be designed to be easily removed from their discharge connections and the wet well for inspection or service. Lifting the pumps from their discharge

Bid Set April 2017



connections or the wet well shall require neither the removal of any bolts, nuts or other fastenings nor the need for personnel to enter the pump well.

2.2 CONDITIONS OF OPERATION

A. The pumps shall be as manufactured by Xylem (Flygt) Model NP 3400/705 3-870, Sulzer ABS Model XFP 405M-CB2 860/8, or equal product meeting the detailed requirements of these specifications. If “or equal” pumps are selected by the contractor, all of the information will have to be submitted to the LAWA and LADBS for plan check for approval.

B. Each pump shall be designed for the conditions of service tabulated as follows and shall operate within the system head curve envelope as appended. All pumps with specific speed less than 4,500 (US units) shall have a continuously rising (from runout toward shutoff) head performance curve for stable pump operation from the minimum head operating point to the shut-off head. For pumps where specific speed is greater than or equal to 4,500, the intersection of the pump head and system head curves shall be used to demonstrate stable operation.

C. The pumps shall operate throughout the specified operating range, within the vibration limitations specified in Paragraph 1.05 F.6 above.

D. Each pump shall be designed for the conditions of operation tabulated as follows:

Item Description Design Conditions

Service Stormwater Number of Pumps (operating/standby) 3 (2/1) Maximum Motor Full Load Speed (FLS) (rpm) 890 Horsepower (non-overloading throughout operating range) (HP) 150 Motor Design Voltage/Phase/Frequency 460/3/60 Maximum Anticipated Pumped Fluid Temperature (degrees F.) 90 Minimum Pump Discharge Size (inches) 16 Minimum Base Elbow Discharge Size (inches) 16 Minimum Pump Suction Size (inches) 19.5 Minimum Pump Shut-Off Head at Motor FLS Acceptable Range (minimum/maximum) (feet)

80/90

Flow Rate at Secondary Operation Point (gpm) 6,000 Minimum TH at Secondary Operation Point (feet) 53 Minimum Overall Efficiency at Secondary Operation Point (%)* 65 Maximum NPSH3 at Secondary Operation Point (feet) 18 Intermediate (Design) Point Flow Rate (gpm) 7,200 Minimum TH at Intermediate (Design) Point Flow Rate (feet) 48 Minimum Overall Efficiency at Intermediate (Design) Point Flow Rate (%)*

70

Best Efficiency Point (BEP) Flow Rate Acceptable Range (minimum/maximum) (gpm)

7,500/8,700

Minimum Overall Efficiency at BEP (%)* 70 BEP Location Relative to Intermediate Design Point Right or at

IDP

Bid Set April 2017



Item Description Design Conditions

Primary Operation Point TH (feet) 32 Minimum Flow Rate at Primary Operation Point (gpm) 10,000 Minimum Overall Efficiency at Primary Operation Point (%)* 62 Maximum NPSH3 at Primary Operation Point (feet) 28 Minimum Size Solids Passing (inches) 3 Minimum Submergence Above Pump Casing (feet)/Maximum Duration at Min. Submergence (minutes)

2/15

* Note that minimum overall efficiencies listed are “wire-to-water” in accordance with ANSI/HI 11.6 – latest edition.

E. Each pumping unit and its driving equipment shall be designed and constructed to withstand the maximum turbine run-away speed of the unit due to back flow through the pump.

2.3 PUMP CONSTRUCTION

A. The overall pump design shall combine high efficiency, low required NPSH3, the ability to handle high solids concentrations effectively. The impeller/casing design shall result in a passage free of surfaces to which solid or fibrous materials can adhere and shall be capable of passing fibrous and nonwoven materials. The design shall permit low liquid velocities and gradual acceleration and change of flow direction of the pumped media.

B. All external pump and motor parts shall be of close grained cast iron, ASTM A48 Class 35B construction, with all parts in contact with stormwater protected by corrosion resistant coatings. All external bolts and nuts shall be type 316 stainless steel.

C. Impellers shall be constructed of ASTM A890 cast stainless steel. Impellers shall be dynamically balanced.

D. The impeller shall be a rotodynamic semi-open, solids handling type capable of passing solids either due to internal clearances or other features to facilitate solids processing including a wear plate with groove. The wear plate to impeller clearance shall be easily adjustable without the need for disassembly of the pump or the need to add or remove shims. The impeller may include pump out vanes on the upper shroud to reduce axial thrust and minimize clogging due to debris accumulation around the mechanical seal. The impeller shall be two-plane dynamically balanced in accordance with ISO 1940-1 quality grade G2.5 standard to provide smooth, vibration free operation.

E. If part of standard pump configuration, a casing wear ring or plate shall be installed to provide efficient sealing between the casing and the impeller. The wear ring shall consist of a stationary ring made of stainless steel fitted to the casing inlet or a stainless steel wear plate installed in the lower half of the casing. Alternative materials and design approaches shall be as approved by the Engineer.

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F. Each pump shall be provided with a balanced tandem mechanical shaft seal system. The upper (inner) of the tandem set of seals shall operate in a seal lubricant chamber located just below the stator housing. At a minimum, this set shall contain one stationary silicon carbide and one positively driven rotating carbon ring and shall function as an independent secondary barrier between the pumped liquid and the stator housing. The lower (outer) of the tandem set of seals shall function as the primary barrier between the pumped liquid and the stator housing. This set shall consist of a stationary ring and a positively driven rotating ring, both of which shall be either tungsten carbide or silicon carbide. Each interface shall be held in contact by its own Hastelloy-C® or Elgiloy® spring system. The seal body shall be Type 316 stainless steel. The o-rings shall be FKM (Viton)®.The seals shall require neither maintenance or adjustment, but shall be easily inspected and replaceable. Seal design shall provide pressure applied to the outside diameter of the face. Shaft seals with conventional double mechanical seals containing either a common single or double spring acting between the upper and lower units are not acceptable nor equal to the dual independent seal specified.

G. The minimum pump discharge size, shall be the minimum allowable nominal diameter

of the discharge connection as shown on the Drawings, except as allowed otherwise by this specification. Unless otherwise noted, the diameter of the opening at the connection between the pump and the discharge connection should normally be the same as the minimum specified discharge size.

H. A sliding guide bracket shall be an integral part of or bolted to the pumping unit. The pump casing shall have a machined connection system to attach to the ASTM A48, Class 35 cast iron discharge connection. The sealing system shall consist of two machined metal to metal flanges or flanges with a replaceable rubber seal, form fitted to the machined discharge coupling to ensure and guarantee a positive leak proof system and to provide ease of pump removal. The discharge connection shall be bolted to the floor of the wet well with type 316 stainless steel sleeve cast-in anchor bolts, monel nuts and accessories and so designed as to receive the pump connection without the need of any bolts or nuts. The pump shall be tightly sealed against the discharge connection and shall be accomplished by a simple linear downward motion of the pump with the pumping unit guided by two guide rails as specified below. No portion of the pump shall bear directly on the wet well floor.

I. Each pump shall be fitted with a Type 316 stainless steel lifting cable and a short piece of suitably sized Type 316 stainless steel chain between the bail and cable. The lifting cable and chain shall be rated for five times the pump weight (minimum).The lifting cable and chain combined length shall be equal to the wet well depth (top slab finished grade to wet well bottom) plus six feet to permit raising the pump for inspection and removal.

J. The lifting cable shall be attached to a lifting bail on the pump. Eyebolts will not be

considered as an acceptable alternate to a lifting bail.

2.4 SUBMERSIBLE MOTORS

A. Pump motors shall be housed in an air filled, water-tight casing, and shall have Class F or better non-hygroscopic insulated windings which shall be moisture resistant. The

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motors shall be suitable for use with the soft starters. The motor stator shall be dipped and baked three times in a VPI process and heat shrunk fitted into the stator housing. As an alternative, trickle impregnation method may be used for motor stator windings. The use of bolts, pins or other fastening devices requiring penetration of the stator housing is not acceptable. Motors shall be NEMA Design B, equipped with a 1.15 service factor, as defined in the NEMA MG1 standard, based upon the nameplate horsepower rating for across-the-line service. The motor insulation system shall be rated at 155 degrees C or better. Motor shall be capable to operate in an ambient temperature of 40 degrees C continuously with Class B temperature rise. The motor shall be NEMA Starting Code G or H, or better. Motors shall be non- overloading and capable of sustaining a minimum of ten starts per hour. Upper motor bearing shall be insulated. Motors shall be provided with a minimum power factor of 0.80 at full load. The motor efficiency shall comply with the minimum established herein: 93 percent at full load to meet the wire-to-water efficiency specified in paragraph 2.02.

B. Pump motors shall have cooling characteristics suitable to permit continuous operation in a partially-submerged condition. Each motor shall incorporate three overheat sensing devices, one in each motor winding. These devices shall trip at 140 degrees C. The sensing device shall be wired into the pump controls in a manner such that if the device operates, the pump will shut down. The temperature device shall be self-resetting.

C. When applied in wet pit application, the pump motors shall be designed so that the pump will be capable of running continuously in a totally dry condition under full load without damage for a cleaning cycle (15 minutes maximum). Pump motor shall be non-overloading within the range of operation between shutoff and the low head runout conditions shown on the pump conditions of operation data table above. For pumps where specific speed is greater than or equal to 4,500, the range from the pump head and system head curves intersection point and low-head run out conditions shall be used to demonstrate non-overloading over the range of operating conditions.

D. The pump/motor shaft shall be constructed of type 420 or type 431 stainless steel. When operating at the pump design point, the shaft shall have a maximum deflection of 0.2 mm at the lower seal face and a maximum deflection of 0.45 mm at the wear ring area. The shaft shall rotate on permanently lubricated ball bearings properly sized to withstand the axial and radial forces. The ABMA Minimum L-10 bearing life shall be at least 30,000 hours rated at the pump BEP.

E. The pump motor with its appurtenances and cable shall be capable of continuous

submergence underwater without loss of watertight integrity to a depth of 65 feet. All mated surfaces shall be machined, fitted with O-rings for watertight sealing.

F. The pumps shall be provided with a cable entry design that shall preclude specific torque requirements to insure a water tight and submersible seal. The cable entry shall be certified by UL or FM to have passed pull-testing requirements. The cable entry junction chamber and motor shall be separated by a stator lead, sealing gland or terminal board, which shall isolate the motor interior from foreign material gaining access to the pump motor top. The cable entry system shall be field serviceable. The

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power and control cable entry into the lead connection chamber may also be epoxy encapsulated for positive moisture sealing. A BUNA-N cable grommet shall be provided in addition to the epoxy sealed leads.

G. Cables, Conduits and Accessories

1. The pumps shall be supplied with power and sensor conductors. Pump motor cables shall be sized to meet applicable NEC requirements. The cable shall consist of a type SPC or SEOW insulated cable with a double jacketed protection system. The cable shall have a neoprene or chlorinated polyethylene outside and synthetic rubber inside, and shall exceed industry standards for oil, gas and sewage resistance. Individual conductors shall be of type RUW. Pump cables shall be provided of sufficient length so that the cables will be continuous between the pump and the disconnect with no splices being allowed.

2. If more than one cable is being provided per pump, the Contractor shall furnish and provide for the installation of the additional conduits, etc. as required for each additional cable. Only one cable per conduit will be allowed at the pump station. Conduit sized per manufacturers recommendations but not smaller than 3/4-inch.

3. Contractor shall furnish all required stainless steel conduit hardware and fittings.

4. Water tight connectors shall be equal to Crouse-Hinds Type "CGB", with neoprene lands shall be furnished with and installed in the control panel enclosure or disconnect to terminate each conduit and seal each cable entry.

5. Conduit seals shall be equal to Crouse-Hinds Type "EYS".

6. Each cable shall be furnished with stainless steel Kellems grip for support with corresponding hook to be mounted to bottom of concrete top slab by the Contractor.

7. Coordinate the installation of the above materials with the Manufacturer.

2.5 PUMP/MOTOR PROTECTION SYSTEM

A. A pump/motor protection system shall be provided to monitor machine temperature, and moisture. The system shall provide warning and shutdown protection and shall be UL listed. All of the pump/motor unit protective and monitoring sensors shall be connected to an electronic module which will provide a signal from the pump/motor sensors to the devices located in the electrical/instrumentation panel. Modules shall be mini-CAS as manufactured by Xylem with associated adaptors, appurtenances and relays.

B. Panel mounted devices shall be located within the electrical/instrumentation panel enclosure provided as part of project for WWF PS by the Contractor. Contractor shall fully coordinate the pump protection device requirements of the Manufacturer with the electrical/instrumentation panel furnished for the project.

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C. Manufacturer shall provide all transformers required to step 460V to required voltage(s) for pump/motor protection system components.

D. Detailed operational data shall be accessible using a standard web browser on a computer with no special software required (future function).

E. The pump/motor protection system shall monitor each pump/motor’s temperature, and moisture (leakage). The system shall be provided with Ethernet, Modbus and modem communications ports, and shall be capable of communicating with a distributed control system in the future.

F. The pump/motor protection module, relays and associated devices shall be mounted within the new electrical/instrumentation panel for WWF PS. The pump/motor protection components shall include leakage and temperature alarm indication, power applied indication, temperature alarm reset mode selection switch, temperature alarm reset push-button and sensor input transient and short circuit protection.

G. Each pump/motor unit(s) shall be equipped with the Manufacturer selected

temperature and moisture monitoring devices from the following protection and monitoring sensors:

1. Three motor winding bi-metalic thermal switches or thermistors, one installed in each motor stator phase winding, and connected in series to monitor and protect the winding from over temperature operation. The thermal switches shall open, activating an alarm and stopping the motor should a high temperature event occur.

2. One PT-100 (Platinum, 100 ohm, 2 or 3-wire) temperature probe shall be installed in the bearing housing holding the outer race of the thrust bearing and lower support bearing to provide for accurate temperature monitoring of the bearings.

3. Three PT-100 (Platinum, 100 ohm, 2 or 3-wire) temperature probes, one installed in each motor stator phase winding, to provide direct stator temperature read-out of each phase winding.

4. One PT-100 (Platinum, 100 ohm, 2 or 3-wire) temperature probe shall be installed in the bearing housing holding the outer race of the upper support bearing to provide for accurate temperature monitoring of the bearing.

5. One Float-type Moisture (Leakage) Sensor (Stator FLS) shall be provided to detect water intrusion into the motor stator chamber. If activated, the FLS will activate an alarm.

6. One Float-type Moisture (Leakage) Sensor (Electrical Connection FLS) shall be provided to detect water intrusion into the motor electrical connection (cable junction) chamber. If activated, the FLS will activate an alarm.

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7. One water-in-oil or water-in-air capacitive type moisture sensor installed in the mechanical seal lubrication chamber (between the inner and outer mechanical seals) to alarm should there be intrusion of water into the chamber.

8. All relays associated with the monitoring and protective devices shall be furnished.

2.6 GUIDE RAILS AND PUMP LIFTING DEVICE

A. The pump station shall be furnished with dual guide rails and associated appurtenances specified herein for each WWF pump and for the portable dewatering pump.

B. The pump station shall be furnished with the necessary, stainless steel upper guide holder and level sensor cable holder.

C. Lower guide holders shall be integral with the discharge connection. Dual guide rails shall be of Schedule 40, welded two-inch minimum diameter, Type 316 stainless steel pipe of the length required by the Drawings. Single guide rails and guide cables are not acceptable.

D. Intermediate guide brackets shall be furnished and installed so that the maximum length of unsupported guide rails will be no longer than 10 feet, and shall be fabricated of Type 316 stainless steel.

E. Stainless steel cable holders including the cable hooks shall be fabricated from Type 316 stainless steel plate. Sharp corners and edges shall be ground smooth to prevent abrasion and cutting of electrical cable insulation. The cable holder shall be of sufficient length and strength to provide support for each separate cable, except that the pump power and lift cables may use the same hook position, provided the cables do not foul one another and the lift cable is easily accessed from the hatch opening.

F. Provide a chain and latch device to facilitate pump removal from wet well without a series of incremental lifts. Device shall be designed to be lowered along the guide rails and shall be remotely latched to pump lifting bail without requiring wet well entry.

2.7 SHOP PAINTING

A. Each pump and associated equipment shall be shop-primed and finished-coated in accordance with the Manufacturer's standard practice prior to shipment. Color shall be Manufacturer’s standard. Adequate supply of touch-up paint shall be supplied by the Manufacturer.

B. All interior and exterior wetted surfaces of pumps and exterior of motor enclosure shall be thoroughly cleaned, dry and free of all rust, mill scale, grease, dirt, other foreign matter and supplied with Manufacturer’s standard epoxy coatings.

C. All nameplates shall be properly protected during painting.

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2.8 PHYSICAL MODEL STUDY

A. The Manufacturer shall make arrangements and pay for having a physical model study performed as specified herein. The purpose of the physical model study will be to assess compliance with the Hydraulic Institute Pump Intake Design Standard intake parameters and if not compliant analyze potential modifications to meet the standard and recommend modifications, if needed. The model shall include all major components from the gravity system entrance to screened inlet structure to the inlet structure outlet to wet well and that all flow patterns and other hydraulic conditions in the inlet box will be within the parameters set forth in the Hydraulic Institute Pump Intake Design Standard (ANSI/HI 9.8) and other parameters presented in this paragraph.

B. The Contractor shall include the physical model study schedule time in his project schedule so that there will be no delays in the overall project completion schedule.

C. Physical Model Study Procedure

1. Model Scale and Construction

a. A Froude-scaled, geometrically similar, undistorted three-dimensional model shall be used for the sump (wet well) model studies. In addition to Froude scaling to provide proper simulation of gravity-driven flow phenomena, the model shall be operated in a range of Reynolds numbers such that the viscosity effects on vortex formation and energy losses in the sump structure will also be simulated. A geometric scale model shall be used as necessary to produce pump suction bell/inlet flare Reynolds numbers greater than 1 x 105 to accurately simulate the wet well hydraulics. The model size shall also be such that any viscous and surface tension scale effects in the model will be negligible.

b. The model shall be constructed in accordance with the plans of the pump

station as shown on the Drawings and field measurements by the Contractor, with sides, walls, and bottom consisting of wood and clear plastic material. The clear material shall be provided in critical areas for viewing the flow patterns. The model shall be constructed to include all pump station components that measurably affect the hydraulic flow patterns within the model boundaries subject to Engineer’s approval. Water shall be maintained in a clear clean condition during testing. Provisions shall be made to prevent backflow through any model pump not in operation. The suction inlets of the pumps shall be scaled, but should not contain the pumping element (impeller or other rotating assembly components). In the case of submersible pumps the general outside shape of the motor, casing and discharge pipe shall be simulated but flow shall be withdrawn vertically through the top of the motor location so that the standard roto-meter (swirl- meter) location can be utilized. Velocity measurement equipment shall be located at the impeller location. The rate of discharge shall be measured from each simulated pump by a Venturi meter, elbow meter, or orifice meter and the total pump circuit shall be measured using a calibrated flow measurement device with an accuracy of at least +/- three percent. The

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model shall be capable of delivering a flow up to 120 percent of the required flow as specified.

c. All flow meters and other instruments used in the physical model study shall be

calibrated or referenced, as appropriate, before use on this physical model study.

2. Performance Criteria: The performance criteria for this study shall be consistent with the Hydraulic Institute Standards and are as follows:

a. No organized free-surface or submerged vortex activity is permitted. No

vortex activity greater than Type 1 (surface dimple or general rotation) is acceptable at Froude-scaled model operation.

b. Velocity profile at the pump throat must be within ± ten percent of average.

c. Time-averaged velocity fluctuations must be within ± ten percent of the

mean.

d. The level of prerotation of flow approaching the pump impeller location as indicated by roto-meter (swirl-meter) rotations shall be less than five degrees from axial and steady.

e. The pumping system shall be modeled under adequate combinations of

operating/not operating pump conditions between the three proposed pumps and through a range of possible water levels. The model shall be capable of simulating a fully submerged wet well structure.

f. The modeler will determine the minimum submergence necessary to suppress

free-surface vortex activity as required in Paragraph 2.08 C.2.a. The modeler will also make recommendations and propose modifications to the intakes to minimize the required submergence to greatest extent possible.

3. Instrumentation and Documentation

a. The following data shall be acquired in the model during each test by using the indicated instruments:

Measure of Observation Instrument Total flow rate and flow rate for each operating pump

Laboratory standard calibrated orifice flow meter, venturi meter, mag meter, or approved other

Water levels and head loss measurements

Precision point gauge referenced to model elevation datum

Velocities at impeller entrance

Miniature rotor velocity meter or pitot- static probe installed in model pump bell throat so as to measure on a constant radius at any location

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Measure of Observation Instrument Prerotation Neutrally pitched four-bladed roto-meter

(swirl-meter) on free-turning bearings four throat diameters downstream from the fixed velocity probe in the model pump bell throat

Vortex formation Visual observation and still photo documentation of injected dye

b. Time-averaged velocity fluctuations shall be measured using a velocity probe sampling discretely at a minimum of 240 Hz. The data shall be analyzed by using a personal computer to determine the standard deviation of the fluctuations.

c. A computer shall be used to enter data into a spreadsheet template as they are

acquired. The template shall convert measured values, i.e., point-gauge reading, manometer differentials, velocity measurements, roto-meter (swirl- meter) indicated swirl angles, etc., into prototype engineering units so data may be reviewed for consistency and trends as they are generated. The modeling firm’s project manager shall verify the formulae used in the template before use, thereby providing a check on all data reduction calculations.

4. Test Program: Prior to proceeding with the physical model study, the modeler shall submit to the Owner and Engineer through the Manufacturer for approval, a full description (including outline drawings) of physical model and the flow-loop (test set-up) and the method of instrumentation. Unless approved otherwise, the test program shall be conducted in three distinct phases:

a. Baseline tests:

1) Baseline tests shall be performed to document intake (sump) hydraulic performance in the model with the proposed design. Baseline tests shall be performed through a range of operating scenarios to determine the most critical condition. A minimum of six documentation tests are anticipated.

2) After completion of baseline testing, the results shall be discussed verbally with the Owner and Engineer to identify significant items that could affect the approach to design development testing.

b. Design Development Tests:

Design development (remedial modification) tests shall be performed to correct any performance deficiencies. During design development testing, the Owner and Engineer shall be kept informed of progress. Following the design development testing an unwitnessed one day test shall be held at the modeler’s facility to demonstrate the model with and without any proposed modifications. Given the limitations and constraints when working with solids bearing fluids all proposed modifications shall be discussed with the Engineer prior to any witness testing. Modifications shall be developed which will minimize solids or grease accumulation as well as rag or debris fouling.

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c. Final Documentation Test: Final documentation test shall be performed with the recommended design, as developed by the modeler. The tests shall be conducted in the same manner as in the baseline tests with one to three pumps operational in each test. The laboratory shall perform a sufficient number of tests to show that the modifications provide hydraulic conditions consistent with the performance criteria for the range of possible operating conditions. The final test program shall be approved by the Engineer prior to testing. A minimum of six documentation tests are anticipated.

5. Physical Model Study Test Report

a. The modeler shall prepare a final report on the physical model study. The report shall include a description of model fabrication, similitude and scaling criteria, and instrumentation; a discussion of test results; tabulated test data; drawings of the physical model study arrangement; drawings of recommended design revisions; and color photos of pertinent flow phenomena. Instrument calibration data shall be included in an appendix.

b. An electronic copy in PDF format, of the draft report shall be submitted to the

Owner and the Engineer unless otherwise specified. Upon completion of incorporation of review comments, five copies of the signed and sealed final report shall be prepared and an electronic copy in PDF format. The final report shall include a narrated videotape or DVD of the Baseline and Final Documentation Testing with copies for the Owner and the Engineer.

6. Physical Model Study Schedule

a. The model shall be designed and constructed, all tests conducted, and the Draft Report delivered to the Owner and Engineer within 12 weeks or a specified duration depending on the extent of modeling following notice to proceed. The Final Report shall be delivered within ten working days following receipt of the Owner’s and Engineer’s comments on the Draft Report.

7. Modeler Qualifications

a. Pump manufacturer shall select a modeler who is acceptable to the Owner and Engineer, and is professionally recognized and regularly engaged in conducting hydraulic modeling studies of major pumping installations. The test shall be managed by a registered Professional Engineer with a minimum of ten years of experience conducting physical model studies with specific experience modeling wastewater and stormwater pump stations.

b. The chosen modeler shall have the complete in-house capability to perform the

entire physical model study with their own personnel in their own facility. Acceptable modelers are Clemson Engineering Hydraulics of Anderson, SC and Alden Laboratories of Holden, MA.

c. Other firms will be considered upon review and approval by the Owner and

Engineer of credentials, including experience record, physical facilities, staff

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background, and references. Testing and modeling facilities owned and operated by the pump manufacturer will be considered for approval on the same basis as described above for any other modeler.

PART 3 EXECUTION

3.1 INSTALLATION

A. Installation shall be in strict accordance with the Manufacturer’s instructions and recommendations in the locations shown on the Drawings. The Contractor shall furnish all required oil and grease for initial operation, if required, in accordance with the Manufacturer’s recommendations. Anchor bolts shall be set in accordance with the Manufacturer’s recommendations.

B. Upon completion of each pump application, the Manufacturer shall inspect the installation and submit a certificate stating that the installation of the equipment meeting Manufacturer’s installation, operation and maintenance manuals is satisfactory, that the equipment is ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication and care of each unit.

3.2 INSPECTION AND TESTING

A. General

1. The Engineer shall be notified in writing prior to initial shipment and/or testing, in ample time so that arrangements can be made for inspection by the Engineer.

2. Field tests shall not be conducted until such time that the pumping system, including controls, is complete and ready for testing.

B. Factory Pump Test

1. All pumps shall be witness tested by the Manufacturer in the presence of up to two persons designated by the Engineer and the Owner. All witness travel and out-of-pocket expenses shall be included in the Contractor’s bid. Expenses include airfare, automobile expenses, lodging, meals, parking, tolls, taxi or car rental costs and the Engineer's time billed at $2,000 per day. Air travel shall be from the airport closest to the Owner’s facility to the airport closest to the Manufacturer’s test facility. The production and testing may occur outside the United States and test will take place in a minimum of a single session of five, eight hour working days, including travel. If additional testing days are required, either because of Manufacturer's scheduling requirements or because a pump has to be retested, the Manufacturer, through the Contractor shall reimburse the Engineer for all reasonable expenses which the Engineer will incur in order to witness the international/ additional testing over that specified herein. The sum shall be deducted from payments due the Contractor by the Owner.

2. The Manufacturer shall factory test all pumps prior to shipment in accordance with the Hydraulic Institute standards, latest version. Flow rate, total head and Input KW shall be tested and recorded for at least five points on the pump

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performance curve. Test shall be performed to demonstrate that the pumps meet ANSI/HI 11.6 acceptance grade 1U for all specified points. The five points shall include the points specified in pump performance table in Paragraph 2.02.

3. The pumps shall be tested at 100 percent of the design speed. Reduced speed curves will be determined using affinity laws.

4. The Manufacturer shall perform hydrostatic test on the pressure-containing parts in accordance with ANSI/HI 11.6. Test shall be conducted on each pump prior to shipment.

5. The Manufacturer shall perform the following test on each pump prior to shipment from factory:

a. Megger motor and pump for insulation breaks or moisture.

b. Prior to submergence, the pump shall be run dry and checked for correct

rotation.

c. Pump shall be run for a minimum of 30 minutes in a submerged condition.

d. The pump shall be removed from test tank, meggered immediately for moisture and upper and lower seal unit shall be checked for water intrusion.

e. A written certification test report regarding the above tests shall be

submitted for approval prior to shipment.

C. Field Pump Test

1. As specified in Paragraph 1.07 B., the Manufacturer shall furnish the services of a representative who shall have complete knowledge of proper operation and maintenance to inspect the final installation and supervise the test run of the equipment. The Manufacturer shall include in his price, a minimum of eight hours of a representative's time for the above tests.

2. Written test procedures shall be submitted to the Engineer for approval 30 days prior to testing.

3. The Contractor shall furnish all water, power, facilities, labor, materials, supplies and test instruments required to conduct the field testing.

4. The Final Acceptance Test shall demonstrate that all items of these Specifications have been met by the equipment as installed and shall include, but not be limited to, the following tests:

a. That the quick release lift out feature functions properly and allows the pump to

be raised and lowered without draining the pit.

b. That all units have been properly installed and are in correct alignment.

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c. The Contractor shall check for correct lubrication in accordance with manufacturer's instructions. The Contractor shall check direction of rotation of all motors and reverse connections, if necessary.

d. That the units operate without overheating or overloading any parts and

without objectionable vibration.

e. That there are no mechanical defects in any of the parts.

f. That the pumps can deliver the specified total head and flow rate to demonstrate that the pumps generally meet the requirements specified (factory performance test is the basis of pump acceptance).

g. That the pump sensors and controls perform satisfactorily as to sequence

control, correct start and stop elevations, and proper level alarm functions.

5. If the pump performance does not meet the specifications, corrective measures shall be taken or pumps shall be removed and replaced with pumps which satisfy the conditions specified.

6. A continuous operating period of the pumps will be required before acceptance. If pumping system fails during the test period, the test shall be restarted (including reset of time to zero) after repair (or replacement) has been completed.

D. Field Vibration Testing

1. After installation and as soon as conditions permit full speed operation, and in the presence of the Engineer, have the vibration tests performed in accordance with ANSI/HI 11.6 on each unit to (a) prove compliance with specified limitations, and (b) prove that there are no field installed resonant conditions due to misalignment, the foundation, or the connecting piping and its supports, when operating at any speed within the specified operating range.

END OF SECTION

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Bid Set April 2017

Pre-engineered Canopy 13120 - 1


SECTION 13120

PRE-ENGINEERED CANOPY

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and design, fabricate, deliver to project site and erect the pre-engineered canopy as shown on the Drawings and as specified herein.

B. Material furnished shall include the structural framing, connections, and anchor bolts; metal panel roofing; gutters and downspouts, flashing, closures, fasteners, and sealants within systems; and all other component parts.

C. Provide the services of a professional Civil or Structural engineer registered in the State of California to be the Engineer of Record and fulfill all requirements of the 2013 California Building Code with 2014 Los Angeles Building Code Amendments, for the work of this Section.

1.2 RELATED WORK

A. Seismic design criteria is included in Section 01612.

B. Wind design criteria is included in Section 01614.

C. Concrete and reinforcing steel is included in Section 03301.

D. Grouts is included in Section 03600.

E. Miscellaneous metals is included in Section 05500.

F. Paints is included in Division 09.


A. American Society of Civil Engineers (ASCE)

1. ASCE 7 – Minimum Design Loads for Buildings and Other Structures.

B. American Society for Testing and Materials (ASTM)

1. ASTM A36 – Standard Specification for Carbon Structural Steel.

2. ASTM A325 – Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength.

3. ASTM A446 – Standard Specification for Steel Sheet Zinc-Coated (Galvanized) by

the Hot-Dipped Process, Structural (Physical) Quantity.

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4. ASTM A500 – Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes.

5. ASTM A529 – Standard Specification for High-Strength Carbon-Manganese Steel of Structural Quality.

6. ASTM A563 – Standard Specification for Carbon and Alloy Steel Nuts.

7. ASTM A572 – Standard Specification for High-Strength Low-Alloy Columbium- Vanadium Structural Steel.

8. ASTM A992 – Standard Specification for Structural Steel Shapes.

9. ASTM F436 – Standard Specification for Hardened Steel Washers.

10. ASTM F1554 – Standard Specification for Anchor Bolts, Steel, 36, 55, and 105-ksi Yield Strength.

C. American Institute of Steel Construction (AISC):

1. Steel Construction Manual – 14th Edition.

D. American Iron and Steel Institute (AISI):

1. North American Specification for the Design of Cold-Formed Steel Structural Members – 2007 Edition.

E. American Welding Society (AWS):

1. AWS D1.1 – Structural Welding Code Steel.

F. California Building Standards Commission

1. California Building Code – 2013 Edition with Los Angeles Building Code Amendments.

G. Society for Protective Coatings (SSPC)

1. SSPC-SP3 – Surface Preparation Specification No. 3 Power Tool Cleaning.

H. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.


A. Columns and beams of rigid frame construction as primary structural supports and other systems specified in this Section, all as approved providing clear inside height and width shown on the Drawings.

B. Bracing in roof and between columns shall be furnished and installed where required

and approved to provide rigidity against wind and seismic loads.

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C. Overall dimensions of the structure, number and length of bays and roof slope as shown on the Drawings.

D. Provide additional framing as required for preformed metal panels, piping supports, lighting fixtures, and other appurtenances and electrical and instrumentation components.

1.5 SUBMITTALS

A. All submittals shall be in accordance with Section PR-9.

B. Submit design calculations for the entire structure, including the anchorage to the concrete foundation, to the Engineer for review. Calculations shall be signed and sealed by a Professional Civil or Structural Engineer registered in the State of California.

C. Submit to the Engineer for review complete plans showing superstructure column lines set to coordinate with concrete footing dimensions shown. Indicate also anchor bolt locations and reactions in KIPS, for all load cases, at all columns. Complete design in accordance with Sections 01612 and 01614.

D. Submit product information, specifications and installation instructions for all components and accessories proposed. Submit standard and custom color charts for color confirmation by the Owner.

E. Submit shop drawings and complete erection drawings for review, including but are not limited to:

1. Anchor bolt and base plate settings.

2. Anchorage supplemental reinforcement or anchor reinforcement, if required.

3. Rigid frames.

4. Roof framing and bracing.

5. Vertical bracing.


A. Deliver, store and handle prefabricated components, and other manufactured items so they will not be damaged or deformed. Stack materials on platforms or pallets, covered with tarpaulins or other suitable weathertight ventilated covering.

1.7 QUALITY CONTROL

A. All items of the same size/type shall be identical and under this Section shall be furnished by a single supplier. The single supplier shall have sole responsibility for furnishing all of the items required for a complete and operable system; however, all components of the system need not be manufactured by a single vendor. The single supplier shall be one of the following:

Bid Set April 2017



1. Varco Pruden Buildings;

2. CECO Building Systems;

3. or approved equal.

PART 2 PRODUCTS

2.1 GENERAL

2.2 DESIGN CRITERIA

A. Primary and secondary members and roof panels shall be designed for all applicable loads and combinations of these loads as set forth in the California Building Code and as shown on the Drawings.

B. Column reactions shall be vertical and horizontal only. No bending moments will be

allowed at the column bases.

C. The design, fabrication and erection of the pre-engineered canopy shall conform to the applicable sections of the latest edition or revision of the codes and standards listed in Contract Documents.

D. The pre-engineered canopy shall be designed to maintain structural integrity and functionality when subjected to the following loads, in addition to the dead load of the structure itself and the wind and seismic loads specified in Sections 01612 and 01614 and shown below.

1. Live Load: The vertical live load of the canopy shall not be less than 20 pounds per square foot applied on the horizontal projection of the roof. Reduction of loads due to tributary loaded areas will not be permitted.

2. Collateral Load: Collateral loads from lighting, conduit, soffit and process piping shall be included in the design of the canopy and shall not be less than 10 psf.

a. Include full collateral load with seismic loads.

b. Do not include collateral loads in load combinations where dead load offsets

other load effects (such as uplift due to wind load).

3. Wind Design Data:

a. Basic Wind Speed: Vult= 110 miles per hour.

b. Wind Exposure Category: C.

4. Earthquake Design Data:

a. Soil Site Class: D.

b. Mapped Spectral Response Accelerations:

Bid Set April 2017



SS = 1.655 g. S1 = 0.616 g.

c. Spectral Response Accelerations: SDS = 1.103 g. SD1 = 0.616 g.

d. Risk Category: II

Ie = 1.0, Ip = 1.0

e. Response modification factor (R): ASCE 7 Tables.

E. Use cast-in-place anchors for concrete anchorage. Anchorage design shall be in accordance with requirements specified in Section 01612.

F. Maximum drift: 0.01 times the canopy height.

2.3 MATERIALS

A. Structural

1. Hot-Rolled Structural Steel Shapes – ASTM A529, A572, A992, or A36.

2. Members Fabricated from Plate or Bar Stock – ASTM A529 or A572; 50,000 psi minimum yield strength.

3. Members Fabricated by Cold Forming – ASTM A1011SS or A1011HSLAS, Grade 55.

B. Structural Framing Components

1. The structural framing shall consist of rigid steel (W-shape) frames, purlins, roof bracing, side vertical bracings, and framing for roof penetrations. Cold formed secondary framing members shall not be fabricated from or contain material less than 16 gauge. Provide supports for soffits, eaves, fire-rated metal panels, pipe supports, lighting fixture supports, and appurtenances as required.

2. Bolts – ASTM F1554 for concrete anchorage and A325 for frame connections as necessary for design loads and connection details.

3. Fabrication - Shop fabricate to the indicated size and section, complete with base plates, bearing plates and other plates as required for erection, welded in place and with all required holes for anchoring or connections shop drilled or punched to template dimensions.

a. Shop connections – power riveted, bolted, or welded

b. Field connections – bolted

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C. Roof System

1. Contractor shall provide standing seam steel roof panels designed in accordance with the design criteria set forth in Paragraph 2.01. Roof panels shall utilize concealed “Z” clips for securing, through appropriate thermal spacers, to purlins, with adjacent panels mechanically seam locked over clips and along their entire lengths. Reinforce, coat, and/ or cover (per manufacturer’s recommendations) panels along gutter where maintenance staff will walk. Roof panels shall be painted white over zinc aluminum coated steel. The panel coating system shall be suitable for a minimum 20-year exterior exposure warranty.

2. Provide flashings, closures for exterior and interior panels, fillers, metal expansion joints, cap flashings, and conduit roof jack flashing, gutters, gutter tailpieces, rain water leaders, and other required sheet metal accessories. Rain water leaders shall be a minimum of 3-inch diameter schedule 40 galvanized steel pipe, attached to columns, and transitioning to cast iron soil pipe at grade.

3. Sheet Panel Fasteners

a. Manufacturer’s standard system of concealed clips, self-tapping screws, bolts and nuts and washers, blind rivets, self-locking bolts, end-welded studs, and other suitable fasteners selected to withstand the design loads.

b. Provide metal-backed neoprene washers under heads of fasteners bearing on

the top side of panels. Metal shall match fastener material.

c. Use stainless steel or aluminum fasteners for all applications.

d. Where exposed, provide fasteners with heads matching color of material being fastened by means of plastic caps or factory applied coating.

D. Vertical Cross Bracing

1. Vertical cross bracing shall be located as shown in the Drawings. Vertical cross bracing shall be only designed to resist tension forces.

E. Structural Steel Surface Coating

1. Primary structural steel members where essentially all surfaces can be field coated after erection shall be shop coated with a primer compatible with the industrial coating system for exterior ferrous non-submerged and exterior galvanized coatings specified in Section 09901. Final coating with these industrial coating systems per Section 09901 shall be completed after all erection is completed.

2. Secondary steel members where one or more surfaces will be covered by adjacent

steel surfaces shall be galvanized. Exposed galvanized steel members shall be coated per the industrial coating system for exterior galvanized coatings per Section 09901.

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PART 3 EXECUTION

3.1 MATERIALS RECEIVED

A. Receive, unload and inspect all metal building components for short and damaged materials. Store off the ground where they will not be soiled, warped, or otherwise damaged. Defective and short materials will be replaced or repaired at no additional cost to the Owner.

3.2 INSPECTION

A. Examine the footings, column supports and the conditions under which work is to be performed and check anchor bolt setting for line and grade. Notify the Engineer in writing of unsatisfactory conditions.

B. Do not proceed with the work until unsatisfactory conditions have been corrected.

3.3 ERECTION

A. Erect structure in accordance with AISC Code of Standard Practice, the approved erection drawings, and the canopy manufacturer's specifications and installation instructions.

B. The pre-engineered canopy shall not be erected until:

1. Structural calculations including foundation reactions, as required to be supplied by the building manufacturer, have been submitted to, and approved by, the Engineer.

2. The column footing design and details, including column anchorage have been approved by the Engineer for the pre-engineered canopy.

C. Anchor bolts shall be installed in concrete footings. Base plates shall be installed and leveled. Anchor bolts shall be double-nutted.

D. Erect structural framing true to line, level and plumb, rigid and secure. Level base plates to a true even plane with full bearing to supporting structures, set with double-nutted anchor bolts. Use a non-shrink grout (1-1/2" min. thickness) to obtain uniform bearing and to maintain a level base line elevation.

3.4 FIELD PAINTING

A. Where exothermic welding (e.g. grounding connections) or attachments to structure were completed and where allowed by the Engineer, touch-up abrasions in factory pre-finished components with air drying paint recommended by the manufacturer of the Section 09902 paint.

B. Apply final coatings per the industrial coatings in Section 09902.

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3.5 PROTECTION AND COMPONENT REPLACEMENT

A. Protect work of this Section from damage by other trades. Correct any painting related damages by cleaning, repairing or replacing and refinishing, as directed by the Owner.

END OF SECTION

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Instrumentation and Controls (IC) - General Provisions

13300- 1


SECTION 13300

INSTRUMENTATION AND CONTROLS – GENERAL PROVISIONS

PART 1 GENERAL

1.1 SCOPE OF WORK

A. The Contractor shall procure the services of a Process Control System Supplier (PCSS) to furnish and install all materials, equipment, labor and services, required to achieve a fully integrated and operational system as specified herein, in the Specification Sections listed below, and in related drawings, except for those services and materials specifically noted. The Contractor/PCSS shall also provide conduit and wiring from the new control panel PLC I/O module to the existing control panel located PLC to lock-out the DWF pumps while any of the WWF pumps are running.

1. Section No Title 13302 I&C - Testing 13303 I&C - Training 13305 I&C - Control Descriptions 13306 I&C - Application Engineering Services 13311 I&C - PLC Hardware and Software 13330 I&C - Control Panels and Panel Mounted Equipment 13335 I&C - Uninterruptible Power Supply (1 Phase) 13340 I&C - Instruments

B. Auxiliary and accessory devices necessary for system operation or performance, such as transducers, relays, signal amplifiers, intrinsic safety barriers, signal isolators, software, and drivers to interface with existing equipment or equipment provided by others under other Sections of these specifications, shall be included and installed whether they are shown on the Drawings or not.

C. All equipment and installations shall satisfy applicable Federal, State and local codes.

D. Use the equipment, instrument, and loop numbering scheme shown on the Drawings and specifications in the development of the submittals. Do not deviate from or modify the numbering scheme without the Engineer's approval.

1.2 RELATED WORK

A. Instrumentation and Controls conduit systems are specified in Division 16.

B. Instrumentation signal cable and alarm and status wiring are specified in Division 16.

C. Relevant equipment Sections in Divisions 11, 13, and 15.

1.3 SUBMITTALS

A. General Requirements:

1. Refer to PR-9 for general submittal requirements.

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2. Shop drawings shall demonstrate that the equipment and services to be furnished comply with the provisions of these specifications and shall provide a complete record of the equipment as manufactured and delivered.

3. Submittals shall be complete; giving equipment specifications, details of connections, wiring, ranges, installation requirements, and specific dimensions. Submittals consisting of only general sales literature shall not be acceptable.

4. Substitutions on functions or type of equipment specified shall not be acceptable unless specifically noted.

5. All instrumentation submittals shall be combined into one package. Individual submittals shall be prohibited.

B. Qualifications Submittal:

1. Submit, within 30 calendar days after Notice to Proceed, detailed information on staff and organization to show compliance with the Quality Assurance requirements of this Section. The Qualifications submittal shall be submitted and approved before any further submittals will be accepted. Failure to meet the minimum requirements shall be grounds for rejection as a PCSS. The Qualifications Submittal shall, as a minimum, contain the following:

a. Copies of ISA CCST Level 1 certificates for all field technicians or resumes

demonstrating field experience.

b. Notarized statement from the firm's financial institution demonstrating ability for the firm to meet the obligations necessary for the performance of the work.

c. Copy of UL-508 certificate for panel fabrication facilities.

d. Project references for water or wastewater projects as defined in the Quality

Assurance paragraphs.

e. Documentation to demonstrate the ability to complete this project including: resumes of key staff, financial capacities, details on engineering, design, fabrication, and field service capacity, and location of staff responsible for responding to the site within four hours to resolve startup issues.

C. Project Plan, Deviation List, and Schedule Submittal:

1. Submit, within 30 calendar days after Notice to Proceed, a Project plan. The Project Plan shall be submitted and approved before further submittals shall be accepted. The Project Plan shall, at a minimum, contain the following:

a. Overview of the proposed control system describing the understanding of the

project work, a preliminary system architecture drawing, interfaces to other systems, schedule, startup, and coordination. A discussion of startup, replacement of existing equipment with new, switchover (Maintaining Plant

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Operations during system transition), approach to testing and training, and other tasks as required by these specifications shall be included as applicable.

b. Preliminary list of OIT software, PLC software, and PLC hardware, including

version numbers, solely to determine compliance with the requirements of the Contract Documents prior to beginning development of system programming. Review and approval of software and hardware systems as part of this Project Plan stage shall not relieve the PCSS of meeting all the functional and performance requirements of the system as specified herein. Substitution of manufacturer or model of these systems after the submittal is approved is not allowed without Engineer approval.

c. Project personnel and organization including the PCSS project manager, project

engineer, and lead project technicians. Include resumes of each these individuals and specify in writing their commitment to this project. These do not need to be submitted again if already submitted in the Qualification submittal.

d. Sample formats of the shop drawings to be submitted and in conformance with

the requirements of the Specifications. At a minimum include samples of panel fabrication drawings, loop, and I/O wiring diagrams.

2. Exceptions to the Specifications or Drawings shall be clearly defined in a Deviation List. The Deviation List shall consist of a paragraph by paragraph review of the Specifications indicating acceptance or any proposed deviations, the reason for exception, the exact nature of the exception and the proposed substitution so that an evaluation may be made by the Engineer. If no exceptions are taken to the specifications or drawings the PCSS shall make a statement as such. If there is no statement by the PCSS, then it is acknowledged that no exceptions are taken.

3. Project schedule shall be prepared in Gantt chart format clearly showing task linkages for all tasks and identifying critical path elements. PCSS schedule must be based on the General Contractor schedule and must meet all field installation, testing, and start-up milestones in that schedule. The project schedule shall illustrate I&C related major project milestones including the following:

a. Schedule for all subsequent project submittals. Include the time required for

Contractor submittal preparation, Engineer's review time, and a minimum of two complete review cycles.

b. Proposed dates for all project coordination meetings.

c. Hardware purchasing, fabrication, and assembly (following approval of related

submittals).

d. Software purchasing and configuration (following approval of related submittals).

e. Shipment of instrument and control system equipment.

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f. Installation of instrument and control system equipment.

g. Testing: Schedule for all testing.

h. Schedule for system cutover, startup, and/or going on-line for each major system. At a minimum include the schedule for each process controller and OIT provided under this Contract.

i. Schedule for all training including submittal and approval of O&M manuals,

factory training, and site training.

j. Incorporate time constraints for AESS activities as defined in Section 13306.

D. Input/Output (I/O) List Submittal:

1. Submit, within 60 days after Notice to Proceed, a complete system Input/Output (I/O) address list for equipment connected to the control system under this Contract.

2. I/O list shall be based on the Drawings, the design I/O list (if included), and requirements in the Specifications.

3. The I/O list shall be submitted in both a Microsoft Excel readable electronic file format and an 8-1/2 inch by 11-inch hard copy.

4. The I/O list shall reflect all active and spare I/O points. Add points to accommodate spare I/O as required in the specifications.

5. The I/O list shall be arranged such that each control panel has a dedicated worksheet. At a minimum, I/O worksheet shall include the following information:

a. TAG NUMBER(S): As indicated on the Drawings, the identifier assigned to a

device that performs a function in the control system. As part of this information, the loop number of the tag shall be broken out to allow for sorting by loop.

b. DESCRIPTION: A description of the function of the device (text that includes

signal source, control function, etc.) Include the text "Spare Points" for all I/O module points that are not connected to equipment.

c. PHYSICAL LOCATION: The Control Panel designation of where the I/O point is

wired to.

d. Physical POINT ADDRESS: Rack, Slot, and Point (or Channel) assignment for each I/O point.

e. I/O TYPE: use DO - Discrete Output, DI - Discrete Input, AO - Analog Output, AI

- Analog Input, PI - Pulse Input, or PO – Pulse Output.

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f. RANGE/STATE: The range in engineering units corresponding to an analog 4- 20 mA signal, or, the state at which the value of the discrete points are "1."

g. ENGINEERING UNITS: The engineering units associated with the Analog I/O.

h. ALARM LIMITS: Include alarm limits based on the control descriptions and the

Drawings.

i. P&ID – the P&ID or drawing where the I/O point appears on. Mark as "NA" (Not Applicable) if the I/O point is derived from a specification requirement and is not on the P&IDs.

6. The I/O list shall be sorted in order by:

a. Physical location.

b. I/O Type.

c. Loop Number.

d. Device Tag.

7. Once the I/O list is approved, the PLC I/O addresses shall not be modified without approval by the Engineer.

8. For I/O layout requirements, see the PLC Section 13311 and Drawings.

E. Hardware and Software Packages Submittal:

1. Refer to the sections below for specific Hardware and Software Packages submittal requirements:

a. 13311 I&C - PLC Hardware and Software.

b. 13330 I&C - Control Panels and Panel Mounted Equipment.

c. 13335 I&C - Uninterruptible Power Supply (1 Phase).

2. For each hardware and software packages component specified in the sections above, submit a cover page that lists, at a minimum, date, specification number, product name, manufacturer, model number, Location(s), and power required. Preferred format for the cover page is ISA-TR20.00.01-2001 (updated in 2004- 2006), general data sheet; however, other formats will be acceptable provided they contain all required information.

F. Testing Plan Submittals:

1. Refer to the 13302 Testing Section for specific testing submittal requirements.

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G. Spares, Expendables, and Test Equipment Lists Submittal:

1. Submit a list of, and descriptive literature for, spares, expendables, and test equipment.

2. Submit a list of, and descriptive literature for, additional spares, expendables, and test equipment recommended by the manufacturer.

3. Submit unit and total costs for the additional spare items specified or recommended for each subsystem.

H. Operations and Maintenance (O&M) Manuals:

1. Submit in accordance with PR-9.

2. Furnish O&M manuals as specified herein. If the PCSS is performing the AE work, provide AE Manuals as specified in Section 13306.

3. The operations and maintenance manuals shall, at a minimum, contain the following information:

a. Table of Contents:

1) A Table of Contents shall be provided for the entire manual with the specific contents of each volume clearly listed. The complete Table of Contents shall appear in each volume.

b. Instrument and Equipment Lists:

1) The following lists shall be developed in Microsoft Excel format and provided not only as a hardcopy in O&M but also electronically on a CD.

2) An instrument list for all devices supplied including tag number, description, specification section and paragraph number, manufacturer, model number, serial number, range, span, location, manufacturer phone number, local supplier name, local supplier phone number, completion year replacement cost, and any other pertinent data.

3) An equipment list for all non-instrument devices supplied listing description, specification section and paragraph number, manufacturer, model number, serial number, location, manufacturer phone number, local supplier name, local supplier phone number, completion year replacement cost, and any other pertinent data.

c. Equipment Operations and Maintenance Information:

1) ISA-TR20.00.01-2001(updated in 2004-2006) data sheets shall be provided for all field instruments. For non-field instrumentation devices, provide a cover page for each device, piece of equipment, and OEM software that lists date, specification number, product name, manufacturer, model number, Location(s), and power required. Preferred format for the cover page is ISA-TR20.00.01-2001(updated in 2004- 2006), general data sheet; however, other formats will be acceptable provided they contain all required information.

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2) Vendor O&M documentation for each device, piece of equipment, or OEM software shall be either new documentation written specifically for this project, or modified standard vendor documentation. All standard vendor documentation furnished shall have all portions that apply clearly indicated with arrows or circles. All portions that do not apply shall be neatly lined out or crossed out. Groups of pages that do not apply at all to the specific model supplied shall be removed.

3) Provide the record documentation of the system audit as specified in the 13302 Testing section.

4) Include the calibration forms developed as specified in the 13302 Testing section.

d. As-Built Drawings:

1) Complete as-built drawings, including all drawings and diagrams specified in this section under the "Submittals" section. These drawings shall include all termination points on all equipment the system is connected to, including terminal points of equipment not supplied by the PCSS.

2) As built documentation shall include information from submittals, as described in this Specification, updated to reflect the as-built system. Errors in or modifications to the system resulting from the Factory and/or Functional Acceptance Tests shall be incorporated in this documentation.

e. Original Licensed Software:

1) Submit original software diskettes or CD-ROMs of all software provided under this Contract. Submit original paper based and electronic documentation for all software provided. Submit license agreement information including serial numbers, license agreements, User Registration Numbers and related information. All software provided under this Contract shall be licensed to the Owner at the time of purchase. Provide media in software sleeves within O&M manual.

f. Electronic O&M Information:

1) In addition to the hard copy of O&M data, provide an electronic version of all equipment manuals and data sheets, along with any software back-up of configuration files, on CDROM or DVD. Electronic documents shall be supplied in Adobe Acrobat format.

2) Provide electronic files for all custom-developed manuals including training manuals. Text shall be supplied in both Microsoft Office format and Adobe Acrobat format.

3) Provide electronic files for all drawings produced. Drawings shall be in AutoCAD ".dwg" format and in Adobe Acrobat format. Drawings shall be provided using the AutoCAD eTransmit feature to bind external references, pen/line styles, fonts, and the drawing file into individual zip files.

4) Each computer system hardware device shall be backed up onto CDROM or DVD after Substantial Completion and shall be turned over to the Owner.

5) If specified in the training section, provide digital copies of all training videos. Videos shall be in a format that is readable by standard DVD

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players and by standard PC DVD drives. Format shall be a minimum of 800 by 600 pixels and shall include sound.

4. The cover and edge of each volume shall contain the information as specified in PR-26 and PR-27.

1.4 COORDINATION MEETINGS

A. Schedule the mandatory coordination meetings as described herein. The meetings shall be held at the Owner's designated location and shall include attendance by the Owner, the Engineer, the Contractor, the PCSS's Project Engineer, and the AESS Project Engineer, if applicable. Other Division 13 specifications may require additional meetings. Prepare and distribute an agenda for this meeting a minimum of one week before the scheduled meeting date. Meeting shall be scheduled a minimum of one week before the requested meeting date.

1. A project kickoff coordination meeting shall be held within two weeks after

submitting the Project Plan. The purpose of the meeting shall be to discuss the PCSS's Project Plan, to summarize the PCSS's understanding of the project; discuss any proposed substitutions or alternatives; schedule testing and delivery deadline dates; provide a forum to coordinate hardware and software related issues; and request any additional information required from the Owner. The meeting will last up to one business day.


A. Publications are referred to in the text by basic designation only. Where a date is given for reference standards, that edition shall be used. Where no date is given for reference standards, the latest edition in effect at the time of bid opening shall apply.

B. International Society of Automation (ISA):

1. ISA S5.2, Binary Logic Diagrams for Process Operations.

2. ISA S5.3, Graphic Symbols for Distributed Control/Shared Display Instrumentation Logic and Computer Systems.

3. ISA S5.4, Instrument Loop Diagrams.

4. ISA S20, Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves.

5. ISA RP60.3, Human Engineering for Control Centers.

6. ISA RP60.6, Nameplates, Labels, and Tags for Control Centers.

C. National Electrical Manufacturers Association (NEMA).

D. National Fire Protection Agency (NFPA):

1. NFPA 70, National Electrical Code (NEC).

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2. NFPA 79, Industrial Control Equipment.

E. Underwriters Laboratories, Inc. (UL):

1. UL 508 - Industrial Control Equipment - for custom fabricated equipment.

2. A nationally recognized testing laboratory, as approved by the Authority having jurisdiction, may substitute for UL listing on commercial off the shelf products.


A. The Process Control System Supplier (PCSS) shall be a "systems integrator" regularly engaged in the design and the installation of instrumentation systems and their associated subsystems as they are applied to the municipal water and wastewater industry. For the purposes of this Specification Section, a "systems integrator" shall be interpreted to mean an organization that complies with all of the following criteria:

1. Employs personnel on this project who have successfully completed ISA or manufacturers training courses on general process instrumentation and configuration and implementation of the specific programmable controllers, computers, and software proposed for this project. Key personnel shall hold ISA CCST Level 1 certification or have a minimum of 10 years of verifiable similar startup experience. Key personnel shall include, as a minimum, the lead field technician.

2. Has successfully completed work of similar or greater complexity on at least three previous projects within the last five years. Successful completion shall be defined as a finished project completed on time, without any outstanding claims or litigation involving the PCSS. Potential references shall be for projects where the PCSS's contract was of similar size to this project.

3. Has been actively engaged in the type of work specified in this Section for a minimum of five years.

B. The PCSS shall maintain a permanent, fully staffed and equipped service facility within 200 miles of the project site with full time employees capable of designing, fabricating, installing, calibrating, and testing the systems specified herein. At a minimum, the PCSS shall be capable of responding to on-site problems within 12 hours of notice. Provide an on-site response within 4 hours of notification starting at two months before scheduled start up to two months after startup completion.

C. PCSS shall hold a valid UL-508 certification for their panel fabrication facility.

D. Actual installation of the instrumentation system need not be performed by the PCSS's employees; however, the PCSS as a minimum shall be responsible for the technical supervision of the installation by providing on site supervision to the installers of the various components.

E. Being listed in this specification does not relieve any potential PCSS from meeting the qualifications specified in this Section.

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A. Delivery, storage, and handling shall be in accordance with Section 01600.

B. Shipping Precautions:

1. After completion of shop assembly, factory test and approval of all equipment, cabinets, panels and consoles shall be packed in protective crates and enclosed in heavy duty (5 mil) polyethylene envelopes or secured sheeting to provide protection from damage, dust and moisture. Dehumidifiers shall be placed inside the polyethylene coverings. The equipment shall then be skid-mounted for final transport. Lifting rings shall be provided for moving without removing protective covering. Boxed weights shall be shown on shipping tags together with instructions for unloading, transporting, storing and handling at the job site.

2. Manufacturer's special instructions for field handling, storage and installation required for protection, shall be securely attached to the packaging for each piece of equipment prior to shipment. The instructions shall be stored in resealable plastic bags or other means of protection.

3. If any apparatus has been damaged, such damage shall be repaired at no additional cost to the Owner.

1.8 NOMENCLATURE AND IDENTIFICATION

A. Field Instrument Tags:

1. See Section 13340.

B. Panel Nameplates:

1. See Section 13330.

1.9 WARRANTY

A. Provide warranty per GC-65 and as specified herein.

1.10 MAINTENANCE CONTRACT

A. A written proposal for a maintenance contract executed by the PCSS shall be provided to the Owner for on-site preventive maintenance services related to the Instrumentation and Control system following the one-year warranty period. The cost of this maintenance contract shall not be included in the Contract Price.

B. This proposal shall be provided within 30 days after final acceptance for the purpose of

entering a contract for annual maintenance subsequent to the first year of maintenance. Standard per diem rates for providing breakdown service shall be set forth in the contract. Such rates shall be fair and reasonable and reflect the lowest rates offered to most favored customers. The fee quoted shall be firm for a minimum of 90 days from date of issue.

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C. This maintenance contract shall include all labor, parts, and emergency calls providing on-site response within 24 hours, to provide complete system maintenance for a period of one year after the date of Substantial Completion of the system for all equipment and software provided as part of the PCSS scope of work.

D. Provide software updates throughout the maintenance contract period. Provide latest

official released version for all software provided under this Contract. Owner shall have the latest software releases at the end of the maintenance contract period.

E. The maintenance contract shall also include a minimum of 4 preventive maintenance visits by qualified service personnel of the Supplier who is familiar with the type of equipment provided for this project. Each preventive maintenance visit shall include routine adjustment, calibration, cleaning and lubrication of system equipment and verification of correct operation.

F. Visits to the sites to correct deficiencies under warranty shall not be included in this preventive maintenance service contract.

G. Emergency maintenance procedures or plant visits may coincide with a preventive maintenance visit; however, they shall not replace the work intended to be performed during a preventive maintenance visit. The Supplier shall have full responsibility for the system hardware preventive and corrective maintenance.

H. During the one-year maintenance period, observation of maintenance operations by LAWA personnel and the instruction of said personnel in the details of the maintenance work being performed, shall be provided.


A. Environmental Requirements. Refer to Division 16 and Electrical Drawings for specific environmental and hazardous area classifications.

B. Elevation: Equipment shall be designed to operate at the project ground elevation.

C. Temperature:

1. Outdoor areas' equipment shall operate between -18 to 50 C degrees ambient. Control panel shall be considered “outdoor” even though it is mounted within the outdoor enclosure.

2. Storage temperatures shall range from 0 to 50 C degrees’ ambient minimum.

3. Additional cooling or heating shall be furnished if required by the equipment as specified herein.

D. Relative Humidity. The other equipment shall operate between 5 to 100 percent relative, condensing humidity.

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PART 2 PRODUCTS

2.1 GENERAL

A. All instrumentation and electronic equipment shall be of the manufacturer's latest design, utilizing printed circuitry and epoxy or equal coating to prevent contamination by dust, moisture and fungus. The field mounted equipment and system components shall be designed for installation in dusty, humid and slightly corrosive service conditions.

B. All instruments shall be provided with mounting hardware and floor stands, wall brackets, or instrument racks unless otherwise noted. Fasteners for securing control panels and enclosures to walls and floors shall be either hot-dipped galvanized after fabrication or stainless steel. Provide stainless steel fasteners only in corrosive areas rated NEMA 4X on the Drawings or as defined under Division 16. Provide minimum size anchor of 3/8-inch.

C. All indicators shall be linear in process units, unless otherwise noted. All transmitters shall be provided with indicators in process units, accurate to two percent or better.

D. All equipment, cabinets and devices furnished shall be heavy-duty type, designed for continuous industrial service. The system shall contain similar products of a single manufacturer, and shall consist of equipment models, which are currently in production. All equipment provided shall be of modular construction and shall be capable of field expansion.

E. All electronic/digital equipment shall be provided with radio frequency interference protection.

F. Electrical:

1. Equipment shall operate on a 60 Hertz alternating current power source at a nominal 120 volts, plus or minus 10 percent, except where specifically noted. Regulators and power supplies required for compliance with the above shall be provided between power supply and interconnected instrument loop. Where equipment requires voltage regulation, constant voltage transformers shall be supplied.

2. With the exception for field device network connected devices, all electronic instrumentation shall utilize linear transmission signals of isolated 4 to 20 mA DC (milliampere direct current) capable of driving a load up to 750 ohms, unless specified otherwise. However, signals between instruments within the same panel or cabinet may be 1-5 VDC (volts direct current).

3. Outputs of equipment that are not of the standard signals as outlined, shall have the output immediately raised and/or converted to compatible standard signals for remote transmission. No zero-based signals will be allowed.

4. All switches shall have double-pole, double-throw contacts rated at a minimum of 600 VA, unless noted otherwise.

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5. Switches and/or signals indicating an alarm, failure or upset condition shall be wired in a fail-safe manner. A fail-safe condition is an open circuit when in an alarm state.

6. Materials and equipment shall be UL approved whenever such approved equipment and materials are available.

7. All equipment furnished shall be designed and constructed so that in the event of power interruption, the systems specified herein shall go through an orderly shutdown with no loss of memory, and shall resume normal operation without manual resetting when power is restored, unless otherwise noted.

2.2 ELECTRICAL SURGE PROTECTION

A. General - Surge protection shall be provided to protect the electronic instrumentation system from induced surges propagating along the signal and power supply lines from lightning, utility, or the plant electrical system. The protection systems shall be such that the protective level shall not interfere with normal operation, but shall be lower than the instrument surge withstand level. Protection shall be maintenance free and self-restoring. Devices shall have a response time of less than 50 nanoseconds and be capable of handling a discharge surge current (at an 8x20µs impulse waveform) of at least 8 kA. Ground wires for all instrumentation device surge protectors shall be connected to a low resistance ground in accordance with Division 16.

B. Provide protection of all analog signal (4-20 mA) circuits where any part of the circuit is outside of the outdoor enclosure. Circuits shall be protected at both the transmitter and the control system end of the circuit. Protection devices located near the transmitter shall be mounted in a separate NEMA 4X 316 stainless steel enclosure (plastic is not acceptable) or conduit mounted, and shall be Phoenix Contact PT Series, MTL Surge Technologies (Telematic) TP48, Citel TSP-10 series, or equal. Substitution of a single device to protect both 120 VAC and 4-20 mA wires to an instrument is acceptable. Protection devices in control panels shall be MTL Surge Technologies (Telematic) SD Series, Phoenix Contact PT Series, Citel DLA series, or equal.

C. Provide protection of all 120 VAC power feeds into control panels, instruments, and control room equipment. Surge arresters shall be Transtector ACP-100BW Series, Phoenix Contact "Mains-PlugTrab", MCG Surge Protection 400 Series, Citel DS40 series, or equal.

D. Inductive Loads – Provide coil surge suppression devices, such as varistors or interposing relays, on all process controller outputs or switches rated 120 VA or less that drive solenoid, coil, or motor loads.

2.3 SPARE PARTS

A. All spare parts shall be wrapped in bubble wrap, sealed in a polyethylene bag complete with dehumidifier, then packed in cartons and labeled with indelible markings. Complete ordering information including manufacturer's contact information (address and phone number), part name, part number, part ordering information, and equipment name and number(s) for which the part is to be used shall be supplied with the required

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13300- 14


spare parts. The spare parts shall be delivered and stored in a location directed by the Owner or Engineer. The quantity of spare parts shall either be a comprehensive spare parts list recommended by the manufacturer or a comprehensive spare parts list to maintain the device for a minimum of 1 year, whichever is more comprehensive. If the manufacturer does not have a recommended spare parts list, then provide a complete new and unopened device as the spare.

B. Furnish one of each type of installed Surge protection devices.

C. Other spare parts are specified in each section. An overview follows:

1. Devices within Control Panels - See the control panels section.

2. PLC spare parts - See the PLC section.

3. Instrument related Spare Parts - see the Instrument section(s).

2.4 TEST EQUIPMENT

A. Provide all test equipment, instruction manuals, carrying/storage cases, unit battery charger, special tools, calibration fixtures, cord extenders, patch cords, test leads, and miscellaneous items for checking field operation of all supplied equipment.

B. All test equipment shall be wrapped in bubble wrap, sealed in a polyethylene bag with a dehumidifier, then packed in cartons and labeled with indelible markings. Complete ordering information including manufacturer's part number, and equipment name shall be supplied. The test equipment shall be delivered and stored in a location directed by the Engineer.

C. As a minimum, furnish the following test equipment:

1. One complete electronic process calibrator sets with rechargeable batteries, cases, spare fuses, test leads, and PC based software. Provide model 830 as manufactured by Altek, or equal.

2. One portable digital multi-meter (DMM) with rechargeable battery and test leads, and carrying case, Fluke 289 Industrial Digital Multimeter, or equal. Combing the features of the electronic process calibrator and the DMM such as the Fluke 787 Process meter is acceptable.

PART 3 EXECUTION

3.1 GENERAL INSTALLATION

A. Instrumentation and accessory equipment shall be installed in accordance with manufacturer instructions. The indicated locations of equipment, transmitters, alarms and similar devices indicated are approximate only. Exact locations of all devices shall be as approved by the Engineer during construction. Obtain in the field, all information relevant to the placing of process control equipment and in case of interference with other work, proceed as directed by the ENGINEER and furnish all labor and materials

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necessary to complete the work in an approved manner at no additional cost to the Owner.

B. Provide brackets and hangers required for mounting of equipment.

C. The shield on each process instrumentation cable shall be continuous from source to destination and be grounded at only one ground point for each shield.

D. Investigate each space in the building through which equipment must pass to reach its final location. If necessary, ship material in sections sized to permit passing through restricted areas in the building. Provide on-site service to oversee the installation, the placing and location of system components, their connections to the process equipment panels, cabinets and devices, subject to the Engineer's approval. Certify that field wiring associated with the equipment is installed in accordance with best industry practice. Coordinate work under this Section with that of the electrical work specified under applicable sections of Division 16.

E. Provide sunshades for equipment mounted outdoors in direct sunlight. Sunshades shall include standoffs to allow air circulation around the cabinet. Orient equipment outdoors to face to the North or as required to minimize the impact of glare and ultraviolet exposure on digital readouts.

3.2 TESTING

A. Refer to Section 13302.

3.3 TRAINING


END OF SECTION

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Bid Set April 2017

IC - Testing with contractor performing AE 13302 - 1


SECTION 13302

INSTRUMENTATION AND CONTROLS – TESTING

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required to complete the testing of all devices and systems furnished and installed as detailed on Drawings, and as specified herein.

B. Refer to Section 13300 for other general requirements.

1.2 RELATED WORK


B. Division 1 "Equipment Testing and Start-up" Section.

1.3 SUBMITTALS


B. Testing Submittals - Submit, in one submittal, the following testing related documents:

1. Status signoff forms:

a. Develop and submit project specific I/O Status and Automatic Control Strategy signoff forms to be used during factory and field testing to organize and track each loop's inspection, adjustment, calibration, configuration, and testing status and sign off. Include sign-off forms for each testing phase showing all loops. 1) Example forms are shown in the Appendices. 2) Separate forms for factory and field testing can be used, or they can be

combined, at the discretion of the PCSS. 3) Submit testing forms prior to start of testing.

C. Test Documentation:

1. Upon completion of each required test, document the test by submitting a copy of the signed off Testing Status forms. Testing shall not be considered complete until the signed-off forms have been submitted and approved. Submittal of other test documentation, including "highlighted" wiring diagrams with field technician notes, are not acceptable substitutes for the formal test documentation.

1.4 MAINTENANCE


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1.5 COST OF TRAVEL

A. Scheduled tests will only be attended once by Engineer /Owner. If test is not successful, all subsequent tests will be performed at Contractor's expense. Reimburse Owner for all costs, including labor and expenses, invoiced by Engineer and incurred by Owner for subsequent retests.

PART 2 PRODUCTS - NOT USED PART

3 EXECUTION

3.1 TESTING - GENERAL


B. Results of all testing shall be tracked on a project specific status sign off form or similar document. PCSS shall be responsible for maintaining the sheet. Appendix of this Section has an example template for this sheet.

C. Tests the PCSS is required to perform are as follows:

1. Factory Testing:

a. Unwitnessed Factory Test (UFT).

2. Field Testing:

a. Startup Acceptance Test (SAT).

D. Wherever possible, perform tests using actual process variables, equipment, and data. Where it is not practical to test with real process variables, equipment, and data, provide all special testing materials and equipment required for a suitable means of simulation.

E. PCSS shall coordinate all required testing with Contractor, affected Subcontractors, Engineer, and Owner.

F. No equipment shall be shipped to jobsite until Engineer or Owner has received all Factory Testing results and approved the system as ready for shipment.

G. Engineer reserves the right to test or re-test any functions.

H. Correction of Deficiencies:

1. Deficiencies in workmanship and/or items not meeting specified testing requirements shall be corrected to meet specification requirements at no additional cost to Owner.

2. Testing, as specified herein, shall be repeated after correction of deficiencies is made until specified requirements are met. This work shall be performed at no additional cost to Owner.

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3.2 FACTORY TESTING - UNWITNESSED FACTORY TEST (UFT)

A. Purpose of UFT is for PCSS to check system prior to Engineer and/or Owner attending SAT. This type of testing should be part of any quality firm's internal QA/QC procedures.

B. Temporary wiring of primary elements, final control elements, and field-mounted transmitters is not required.

C. Hardware to be tested shall include all the control panel and all monitored and/or controlled devices (e.g. pumps, field devices, etc.).

D. Tests to be performed shall include, but not be limited to, the following. Each of these tests shall be specifically addressed in Test Procedure submittal.

1. All panels and enclosures being provided shall undergo a thorough inspection to verify integrity of cabinet enclosures, frame structures, paint work and finish, etc. Review panel drawings to ensure they accurately reflect panel layout and wiring.

2. Perform a system audit to verify all components have been staged for test and have been documented properly with correct model numbers, serial numbers, etc. Following documentation of audit shall be provided at factory test and submitted as part of O&M Manual Documentation:

a. For each microprocessor-based component part of or connected to control

system (PLCs, I/O cards, instruments, and final field devices, etc.), list firmware revision, vendor and local distributor information, and system, warranty information, configuration parameters (e.g., communication settings, fail position settings, etc.)

3. Panel wire pull tests shall be performed to ensure all wiring has been connected with appropriate torque to prevent wires from coming loose.

4. UPS shall be tested to verify UPS switch power correctly while keeping all UPS powered loads online. Testing of UPS to determine if they have been sized correctly to maintain a minimum run time of 15 minutes shall be performed during field testing.

5. A 100 percent I/O point checkout shall be performed to verify proper operation of input/output points.

6. All control strategies shall be verified using simulation or other means to verify logic performs as expected. Verify faults and logical failure conditions for control strategies such instrument failures, equipment failures, out of range testing (over and under scale) for analog inputs, and all other strategies specified in control strategy document.

7. For each hardware enclosure, inspection shall include, but not be limited to, cabinet enclosures, frame structure, paint work and finish, dimensions, and hardware operability (i.e., fans, door hinges, keylocks, etc.).

Bid Set April 2017



8. For each subpanel, inspection shall include, but not be limited to, I/O subsystem physical layout, power supply sizing and mounting, cable routing, wire runs across hinges properly installed, fans and blowers unobstructed and mounted to maximize air flow, power conditioning correctly installed, and overall layout and installation of components meets manufacturer's recommendations and standard industry accepted practices.

9. All other control panel circuitry.

E. Upon successful completion of UFT, PCSS shall submit a record copy of test results as specified in PART 1. As part of this test results submittal, Engineer and Owner will review UFT test results and will provide questions and/or comments. Once all questions and comments have been addressed to the satisfaction of the Engineer and Owner, the UFT test results will be considered completed.

3.3 FIELD TESTING - SITE ACCEPTANCE TEST (SAT)

A. After completion of installation, and system is started-up and running treatment process in automatic control to extent possible, system shall undergo a test as defined in Division 1 "Equipment Testing and Start-up" Section.

B. While this test is proceeding, Engineer and Owner shall have full use of system. Only Owner operating personnel shall be allowed to operate equipment. Operations shall remain responsibility of Owner and decision of Owner operators regarding operations shall be final.

C. During this test, PCSS personnel shall be present as required to address any potential issues that would impact system operation. PCSS is expected to provide personnel for this test who have an intimate knowledge of hardware and software of system. When PCSS personnel are not on-site, PCSS shall provide cell phone/pager numbers that Owner personnel can use to ensure that support staff is available by phone and/or on- site within four hours of a request by operations staff.

D. Any malfunction during test shall be analyzed and corrections made by PCSS. In event of rejection of any part or function, PCSS shall perform repairs or replacement within 5 days.

E. Throughout duration of SAT, no software or hardware modifications shall be made to system without prior approval from Owner or Engineer.

3.4 CERTIFICATE OF INSTALLATION

A. Following successful completion of SAT test, PCSS shall submit a Certification of Installation for system as required in Division 1 "Equipment Testing and Start-up" Section.

END OF SECTION

Bid Set April 2017



APPENDIX 13302-A: EXAMPLE INPUT/OUTPUT (I/O) STATUS SIGN OFF FORM An example template for I/O Status signoff form to be used for documenting testing results to Owner is attached. PCSS is required, prior to testing, to create a project specific I/O Status signoff form based on attached template or approved equal. PCSS may obtain an electronic copy of template from Engineer or develop it on their own.

APPENDIX 13302-B: EXAMPLE AUTOMATIC CONTROL STRATEGIES SIGN OFF FORM An example template for Automatic Control Strategies signoff form to be used for documenting testing results to Owner is attached. PCSS is required, prior to testing, to create a project specific Automatic Control Strategies signoff form based on attached template or approved equal. PCSS may obtain an electronic copy of template from Engineer or develop it on their own.

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Bid Set April 2017

IC - Training 13303 - 1


SECTION 13303

INSTRUMENTATION AND CONTROLS – TRAINING

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish training as specified herein.

B. This Section covers the training requirements for all devices and systems furnished and installed as detailed on the Drawings.

C. Refer to Section 13300.

1.2 RELATED WORK


1.3 SUBMITTALS

A. Refer to Section 13300 for general submittal requirements.

B. Preliminary Training Plan Submittal

1. Prior to the preparation of the Final Training Plans, submit outlines of each training course including course objectives and target audience, resumes of instructors, prerequisite requirements for each class, and samples of handouts for review.

C. Final Training Plan Submittal

1. Upon receipt of the Engineer's comments on the preliminary training plan, submit the specific proposed training plan. The training plan shall include:

a. Definitions, objectives, and target audience of each course.

b. Schedule of training courses including proposed dates, duration and locations of

each class.

c. Complete copy of all proposed handouts and training materials. Training information shall be bound and logically arranged with all materials reduced to a maximum size of 11 inch by 17 inch, then folded to 8.5 inch by 11 inch for inclusion into the binder.

Bid Set April 2017



PART 2 PRODUCTS

2.01 N/A

PART 3 EXECUTION

3.1 GENERAL

A. The cost of the training programs shall be included in the Contract price. The training and instruction shall be directly related to the system being supplied. The training program shall represent a comprehensive program covering all aspects of the operation and maintenance of the system.

B. All training schedules shall be coordinated with and at the convenience of the Owner. Shift training may be required to correspond to the Owner's working schedule.

C. All onsite instructors must be intimately familiar with the operation and control of the Owner's facilities.

D. Provide detailed training manuals to supplement the training courses. The manuals shall

include specific details of equipment supplied and operations specific to the project. The manuals shall be provided in hardcopy for each student. Provide electronic copy of each training manual in PDF format for Owner's future use.

E. The trainer shall make use of teaching aids, manuals, slide/video presentations, etc. After the training services, all training materials shall be delivered to Owner.

F. The Owner reserves the right to videotape all custom training sessions. All training tapes shall become the sole property of the Owner.

G. Cost of Travel for off-site training

1. Cost of Travel for off-site training shall be paid directly by the entity employing the staff doing the traveling.

3.2 TRAINING SUMMARY

A. The following training courses listed in the summary table shall, as a minimum, be provided:

Description Minimum Course Duration (hours)

Maximum Number of Trainees per Course

Number of Times Course to be Given

Intended Audience

Manufacturer's Training

Programmable Logic Controller (PLC) Basic

32 2 1 TBD

Programmable Logic Controller (PLC) Advanced

32 2 1 TBD

Onsite Training

Bid Set April 2017



Description Minimum Course Duration (hours)



Intended Audience

Control System Overview Seminar Covered in AESS scope of work Operator Control System Training Covered in AESS scope of work Description Minimum

Course Duration (hours)



Intended Audience

Installed Control System 2 2 1 TBD PLC Hardware/Software 2 2 1 TBD Instruments 16 2 1 TBD Instruments - Operator familiarity 2 8 1 TBD Fiber Optics 4 2 1 TBD

B. Definitions of audience roles

1. Administrator - personnel responsible for maintaining the HMI / SCADA system.

2. Maintenance - personnel responsible for maintaining the field controller hardware and instrumentation system.

3. Operations - personnel responsible for daily operations.

4. Management - non-daily operations personnel

3.3 MANUFACTURER'S TRAINING

A. Programmable Logic Controller (PLC) Hardware and Software

1. Provide manufacturer's standard training courses for the Owner's personnel in the operation, configuration, programming, installation, and maintenance of the PLC hardware and software supplied. Conduct this course in separate beginner and advanced training sessions.

2. The training shall be conducted no more than two months before the SAT.

3. The following hardware training shall be provided as a minimum:

a. Hardware maintenance for the PLC equipment provided.

b. Test, adjustment, and calibration procedures.

c. Troubleshooting and diagnosis.

d. Component removal and replacement.

Bid Set April 2017



e. Periodic maintenance.

4. The following software training shall be provided as a minimum:

a. System configuration.

b. Application specific program development/programming.

c. Uploading/downloading programs.

d. Documenting program/configuration.

e. System backups and reload procedures.

f. TCP/IP addressing procedures.

3.4 ONSITE TRAINING

A. Training personnel shall be intimately familiar with the control system equipment, its manipulation, and configuration. Training personnel shall command knowledge of system debugging, program modification, troubleshooting, maintenance procedure, system operation, and programming, and shall be capable of transferring this knowledge in an orderly fashion to technically oriented personnel.

B. Installed Control System Training

1. Provide training for the Owner's personnel in the functionality, maintenance, and troubleshooting, of the installed Control System. The training shall be held before the SAT, but not more than two months before.

2. Training and instruction shall be specific to the system that is being supplied.

3. Training shall consist of classroom instructions and hands-on instruction utilizing the Owner's system.

4. Detailed training shall be provided on the actual configuration and implementation for this Contract. Training shall cover all aspects of the system that will allow the Owner's personnel to maintain, modify, troubleshoot, and develop future additions/deletions to the system. The training shall cover the following subjects, as a minimum:

a. System overview.

b. System hardware components and specific equipment arrangements.

c. Periodic maintenance.

d. Troubleshooting and diagnosis.

e. TCP/IP addressing procedures for all Ethernet devices.

Bid Set April 2017



C. Programmable Logic Controller (PLC) Hardware and Software

1. Provide training for the Owner's personnel in the operation, maintenance, troubleshooting, etc. with the PLC hardware and software system. The training shall be held before the SAT, but not more than two months before.

2. Training and instruction shall be specific to the system that is being supplied.

3. Training shall consist of classroom instructions and hands-on instruction utilizing the Owner's system.

4. Detailed training shall be provided on the actual configuration and implementation for this Contract. Training shall cover all aspects of the PLC system that will allow the Owner's personnel to maintain, modify, troubleshoot, and develop future additions/deletions to the PLC system. The training shall cover the following subjects, as a minimum:

a. PLC system overview.

b. PLC system architecture.

c. PLC system hardware components and specific equipment arrangements.

d. PLC system startup, shut down, load, backup, and PLC failure recovery.


f. Troubleshooting and diagnosis down to the I/O card level.

g. PLC configuration, communications, and operation.

D. Instrument Training

1. Provide instruction on the maintenance of the field and panel instrumentation for the Owner's instrumentation technicians. This training shall be conducted before the SAT, but no more than 1 month before and at a time suitable to the Owner. This training shall take place at the Owner's facility. As a minimum, the following shall be included:

a. Training in standard hardware maintenance for the instruments provided.

b. Specific training for the actual instrumentation configuration to provide a detailed

understanding of how the equipment and components are arranged, connected, and set up for this Contract.

c. Test, adjustment, and calibration procedures.

d. Troubleshooting and diagnosis.


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E. Instruments - Operator familiarity

1. Provide operator level instruction on the use of the field and panel instrumentation for the Owner's operations staff. This training shall be conducted before the 30-day site acceptance test, but no more than 1 month before and at a time suitable to the Owner. This training shall take place at the Owner's facility. Include hands on demonstration of the information each transmitter indicates and the method used to retrieve any operator information from the transmitter, including use of pushbuttons and interpretation of international graphic symbols used on the instruments.

END OF SECTION

Bid Set April 2017

Instrumentation and Controls – Control Descriptions 13305- 1


SECTION 13305

INSTRUMENTATION AND CONTROLS - CONTROL DESCRIPTIONS

PART 1 GENERAL

1.1 SCOPE OF WORK

A. This section is provided to clarify the control strategies to be used to program the system.

B. All PLC controller programming and Operator Interface Terminal (OIT) graphics and programming shall be performed as defined in Section 13300.

1.2 RELATED WORK

Refer to Section 13300.

PART 2 PRODUCTS (NOT

USED)

PART 3 EXECUTION

3.1 GENERAL

A. The control descriptions are sorted by loop number for each area.

B. The control descriptions are broken into a hierarchical layer concept. There may be one layer or multiple layers per loop, depending upon that loop. An example of multiple layered loops is as follows. The lowest layer of control, local control, is at that piece of equipment or that piece of equipment's panel or drive. The second layer of control is at an intermediate control panel between the equipment and PLC I/O. The third layer would be at the vendor's PLC or microprocessor touchscreen station. The PLC performs the actual monitoring and control logic for the process equipment and the operator workstation (OIT), which has a graphical software interface to the PLC software for monitoring and implementing all operator-required tasks to control that process equipment.

3.2 CONTROL FUNCTION DEFINITIONS AND GENERAL CRITERIA

A. The hardware and/or software functions noted by this paragraph reference are to be implemented by the PLC/OIT control system specified herein.

B. The following list of ISA abbreviations is typical of those utilized. The description following the abbreviation summarizes the basic function to be implemented in the PLC/OIT software.

Bid Set April 2017



1. HS: Represent selector switches or pushbuttons, which shall be implemented by keyboard entry. Function shall be similar to their hardware counterparts. Examples are as follows:

a. HSH- Open Command.

b. HSL- Close Command.

c. HSS-Start/Stop Command.

2. YI: Represents equipment status (i.e., availability, running, in remote, etc.) implemented by a change of color on the OIT symbol for this equipment. For motor driven equipment such as pumps, blowers, compressors, etc., availability contact represents remote operation and no alarm conditions. Examples are as follows:

a. YCI-Selector switch in computer, auto or remote position.

b. YRI-Motor running status.

c. YFI- Motor failure or overload status.

d. YMI- Selector switch in maintenance position.

3. PAL, AAH, UA, etc.: Represent high or low alarms implemented on the OIT.

4. FIC, PID, AIC, etc.: Represent PID process controllers implemented in computer logic algorithm incorporating proportional, integral, and/or derivative modes. Local/remote and manual/auto capabilities shall be provided.

5. FI, PI, AI, etc.: Represent digital output display on the OIT display of a process variable in engineering units and/or a dynamic representation of the variable by symbol or graphical means.

6. FIR, PIR, AIR: Represent values stored on the hard disk to provide the data for historical trend graphics of process variables against time (or other selected variables).

7. ZSH, ZSL etc.: Represent high or low, open or close limit positions.

C. Any interlocks that are represented, before the local operational descriptions, or are stated as hardwired interlocks, shall interlock all the controls locally and in the PLC. PLC’s shall be programmed to shut down equipment if the hardwired interlock is also wired to the PLC.

D. Any interlocks that are represented in a particular layer of the operational descriptions, shall interlock all the controls in that layer and the layer above it. However, the interlock shall not interlock the commands in the layer below it.

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E. The PLC shall stop a motor or drive in its program if it does not receive the auto or remote status or one of its software interlocks trip. If the drive or motor is in hand or remote it will continue to run but the PLC start/stop output will be open.

F. Any motor that is requested to start by an operator or an automatic program shall alarm if the run confirm status for that motor does not activate within two seconds. If a motor stops by an interlock or stops without any operator or PLC intervention, then that motor shall go into alarm. Any motors that are stopped by a program or the operator shall not go into an alarm.

G. Motors shall indicate to the operator locally and remotely (OIT) that the motor is running regardless of the operational mode of the motor.

H. All motors shall be programmed so if a motor stops for any failure, it shall not be restarted automatically until the problem with the motor has been resolved.

I. The start command on the OIT shall not be a maintained contact but a momentary

command to the PLC. The run confirms of all motors shall seal in the control output to the motor once the momentary start command drops out. The run confirms shall be on a five second timer delay in that if the run confirm is not present after five seconds, the contact output to the motor from the PLC shall drop out. Thus, the only way a motor can be restarted after five seconds by the PLC is if the operator reinitiates the start command for that motor on the OIT or when that motor control at the OIT is placed in complete automatic mode and the PLC through logic/interlocks requests the motor to run.

J. Terminology associated with interlocks is as follows:

1. When a contact or status is true, the PLC will receive power to its input channel. The PLC registers this as a binary bit of one.

2. When a contact or status is false, the PLC will receive no power (open circuit) to its input channel. The PLC registers this as a binary bit of zero.

K. When an analog signal goes outside the 4-20 mA range due to a failure at the instrument or PLC card, the following programming shall take place:

1. Alarm the signal at the OIT system.

2. If the analog signal is associated with a control loop or ratio control loop that loop shall go into manual.

3. If the analog signal is used in a calculation, that calculation shall use the last good analog signal. The computer shall place the control loop in manual if using the calculation.

L. Disable all alarms on analog inputs unless specifically called for in the drawings or specifications.

Bid Set April 2017



M. All interlocks that shutdown (Stop a piece of equipment and prevent it from being restarted or moved) shall be shown on the faceplate pop-up graphic for that piece of equipment.

N. The run confirms or on status of all motors and lamps shall be accumulated to calculate a run time status of the equipment on the OIT graphic. Each run time accumulation shall come with a reset button on the HMI screen.

O. All flow indications shall be totalized. Do not totalize if the analog signal is outside the 4-20 mA range. Each flow tantalization shall come with a reset button on the HMI screen. Do not totalize if the value of the flow input is less than 2% of the full range of the input.

P. A red alarm beacon light shall be provided and mounted on the control panel shall be initiated upon detection of the following alarms:

1. High hydrocarbon – 70% LEL;

2. High oil in water detection - 10 PPM;

3. High-high basin level – LAHH.

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INSTRUMENTATION AND CONTROLS – LOOP DESCRIPTIONS

LOOP WWF-P1-P3 WET WEATHER FLOW (WWF) PUMPS

A. Process Overview

1. The WWF pumps are not required for low flow operating conditions. Low flow operating condition will be indicated by low level (below lead WWF pump start elevation) in stormwater retention basin. Under those conditions, the stormwater is conveyed though the existing dry weather flow (DWF) pump station to the downstream oil water separator and on to collection system. Therefore, the WWF pumps are not in operation under low flow conditions.

2. For conditions in which WWF pump operation is required (during and after storms which raise the basin level above the lead WWF pump start elevation), one or two WWF pumps will be operational. In normal operation (automatic), the pumps will be controlled by level setpoints in the stormwater retention basin/WWF PS wet well. However, the operator shall have the capability to select automatic operation or requiring manual initiation of operation mode to avoid WWF pump conveyance of a jet fuel spill to the collection system. In manual operation, pumps will be turned on and off by operations staff with low level pump shutoff remaining an active protection function. Under automatic operation the pumps will be turned off if oil in water is detected.

3. The pump motors will be monitored for high temperature, seal leakage, and sensor shorted conditions, and pumps will be shut-off in case any fault is detected.

4. DWF pump operation will be automatically terminated/prevented if WWF pump(s) are operating. After WWF pumps are shutoff the DWF pump operation shall be automatically re-engaged to operate automatically on level.

5. The WWF pumps will sequence on and off based on level and runtime to maintain similar run time for all three pumps. The rotation of pumps during/after a storm event will also minimize accumulation of debris in vicinity of the WWF pump which is not in operation (Standby).

6. The pumps will be operated in a Lead/Lag/Standby mode, based on level in the wet well and stormwater retention basin, and pump runtime.

a. The lead pump will be started at elevation 45.5 (admin adjustable).

b. The lag pump will be started at elevation 50.0 (admin adjustable).

c. The lag pump will be stopped at El 46.0 (admin adjustable).

d. The lead pump will be stopped at El 30.1 (admin adjustable).

Bid Set April 2017



e. The standby pump will replace the lead pump after 3 hours (admin adjustable) of operation.

f. The pumps will cycle on/off on 2-hour (admin adjustable) runtime increments in

order of longest current event runtime. At each transition, the pump will shut down before the replacement pump is started.

7. Associated with pump operation will be the control of the gates at Imperial and Pershing Drive, based on level in the stormwater retention basin.

a. Gates start in the open position.

b. On rising level, Imperial gate closes at El 53.5.

c. On rising level, Pershing Drive gate closes at El 53.5.

d. On falling level, both Imperial and Pershing Drive gates open at El 51.5.

8. Associated with pump operation will be alarms.

a. HHWL Alarm at El 54.5; all gates closed.

b. HWL Alarm at El 50.75.

c. LLWL Alarm at El 29.0; all pumps shut down.

9. In no case shall the flow rate exceed 50 cfs. If this flow rate is exceeded in any operating mode, an alarm will be generated and the pumps will automatically shut down. Operator initiated alarm reset will be required to restart the pumps.

10. The pumps will shut down in the reverse order from which they were started as level set points dictate. The last pump running will shut down at elevation 30.1 (admin adjustable). Below this level all pumps will be turned off and the lead pump will restart when the level reaches elevation stated above (admin adjustable). Pump shut down level shall be set to allow for wet well level rise that will occur after pump shutdown and pump discharge piping upstream of the check valve drains back into wet well.

11. The elapsed run time for each pump will be recorded via elapsed time meter at the CP-1.

12. The failure of an operating pump while in automatic mode will result in an alarm

and the standby pump starting to take the place of the failed pump. The failed pump will not return into service until the alarm is reset by an operator.

13. The pump sequence of operation shall be alternated after all pumps have stopped. Lag pump at end of the previous pump operation will become the lead pump, standby will become lag and lead pump will become standby. The system will automatically rotate pumps in this rotation after each pumping operation to

Bid Set April 2017



distribute run time between the three pumping units. The lead/lag status of each pump shall be indicated on the OIT on the Control Panel.

14. The WWF pumps shall automatically shut-down if High hydrocarbon vapor (70% LEL, operator adjustable 0-100%) or High concentration of oil in water (10 PPM, operator adjustable 0.1-15 PPM) is detected.

B. Control Equipment – WWF Pumps:

1. Each WWF pump soft starter shall include:

a. LOCAL-OFF-REMOTE selector switch.

b. START/STOP pushbuttons.

c. Run time meter (hours).

2. Each pump and motor shall be equipped with moisture and temperature monitoring devices tied back to the pump manufacturer furnished panel and relays as specified in Section 11306. Panel and relays to be located in CP-1.

3. The WWF pump PLC system shall include the control logic to facilitate automatic operation mode and links to the protective/monitoring devices furnished by the pump manufacturer.

C. Control Operations – WWF Pumps:

1. When the LOCAL-OFF-REMOTE selector switch at the soft starter is in LOCAL, the pump motor shall be started and stopped manually at the starter by operator.

2. When the LOCAL-OFF-REMOTE switch at the soft starter is in REMOTE, the pump motor shall be automatically controlled by the WWF pump PLC system.

3. When the LOCAL-OFF-REMOTE switch at the soft starter is in OFF, the pump operation in manual and automatic mode will be disabled.

D. INTERLOCKS:

1. Hardwire: a. None.

2. Software:

a. Stop/prevent running of DWF pumps while any of the WWF pumps are running.

b. Enable operation of DWF pumps on shutdown of all WWF pumps.

c. Automatic shut-down of WWF pumps in case high hydrocarbon vapor or high oil in water concentrations are detected exceeding the limits stated in section A.14 above.

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E. MONITORING:

1. Local: a. Running/Off/Fail status indication at the soft starter. PLC/OIT: a. Running/Off/Fail status indication at the OIT.

F. ALARMS:

1. PLC/OIT: a. Pump Fail.

G. Other control considerations:

1. The WWF pumps will need to be exercised briefly if not operated frequently enough. PLC will track run frequency. Pumps which do not operate for a duration of one month will be automatically started (bumped) for a short duration, 5 seconds initially (admin adjustable), which can occur when wet well is dry.

2. Provide a WWF pump re-start delay of four (4) minutes (admin adjustable) in any operating mode to allow the backspin caused by discharge piping contents reversing flow direction at pump shutdown to be completed before pump restart.

3. Starting of a third WWF pump will be prohibited when there are two WWF pumps running.

LOOP WWF FE/FIT-1 Flow Monitoring

A. PROCESS OVERVIEW:

1. The flow shall be monitored from the Wet-Weather Flow Pumps to the existing NCOS.

2. Refer to Drawing E-3.

B. CONTROL MODES:

1. Field (Local) Control: a. There are no manual controls for the Flow Monitoring.

2. PLC Automatic Control: a. There is no auto control for the Flow Monitoring.

C. INTERLOCKS:


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2. Software: a. When flow goes beyond 50 cfs, stop all operating WWF pumps.

D. MONITORING:

1. Local: a. FIT-1: Flow indication.

2. PLC/OIT:

a. FI-1: Flow Indication. b. FIQ-1: Totalized Flow Indication.

LOOP WWF LE/LIT-1 WWF PS Wet Well and Stormwater Detention Basin Level Monitoring


3. Continuous level measurements at the WWF wet well.

B. CONTROL MODES:

1. Field (Local) Control: a. There are no manual controls for the Level Monitoring.

2. PLC Automatic Control:

a. Under automatic operation, the WWF pumps are started/stopped based on basin level as described under Loop WWF-P1-P3.

C. INTERLOCKS:

1. Hardwire:

a. None.

2. Software: a. None.

D. MONITORING:

1. Local: a. LIT-1: Level indication.

2. PLC/OIT: a. LI-1: Level Indication.

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PLC/OIT:

a. Low-Low level alarm (LALL).

b. Low level alarm (LAL).

c. High level alarm (LAH).

d. High-High level alarm (LAHH). LOOP WWF AE/AIT-1 WWF PS Discharge Oil Monitoring


1. Continuous oil in water measurement at the WWF pumps discharge main.

B. CONTROL MODES:

1. Field (Local) Control:

a. There are no manual controls for the Oil in Water Monitoring.

2. PLC Automatic Control: a. Under automatic operation, the WWF pumps are shut-off if oil in water (10-

PPM-operator adjustable) is detected.

C. INTERLOCKS:


2. Software: a. WWF Pumps shut-off if oil in water 10-PPM or greater is detected (operator

adjustable).

D. MONITORING:

1. Local: a. AIT-1: PPM Oil in water indication.

2. PLC/OIT: a. AI-1: PPM Oil in water Indication.

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1. PLC/OIT:

a. High PPM oil in water alarm (AAH). b. High-High PPM oil in water alarm (AAHH).

LOOP WWF AE/AIT-2 Hydrocarbon Gas Monitoring


1. Continuous hydrocarbon gas measurement at the WWF pumps discharge main

outfall.

B. CONTROL MODES:

1. Field (Local) Control: a. There are no manual controls for the Hydrocarbon Gas Monitoring.

2. PLC Automatic Control:

a. Under automatic operation, the WWF pumps are shut-off if high hydrocarbon gas (70% LEL-operator adjustable) is detected in the outfall.

C. INTERLOCKS:


2. Software: a. WWF Pumps shut-off if high hydrocarbon gas in the outfall is detected (70%

LEL-operator adjustable).

D. MONITORING:

1. Local: a. AIT-2: %LEL Hydrocarbon Gas Indication.

2. PLC/OIT: a. AI-2: %LEL Hydrocarbon Gas Indication.

E. ALARMS:

1. PLC/OIT: a. High %LEL Hydrocarbon Gas alarm (AAH). b. High-High %LEL Hydrocarbon Gas alarm (AAHH).

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LOOP LSH-1/LSL-1 WWF Basin High/Low Level Sensing

A. General:

1. Monitoring of the WWF Basin high/low level switch. These level switch alarms shall be hardwired to the PLC.

B. Control:

1. Local: a. None.

2. SCADA PLC/OWS/OIT: a. None.

C. Alarms / Monitoring:

1. Local:

a. None.

2. PLC/OIT: a. High level switch alarm (LSH). b. Low level switch alarm (LSL).

END OF SECTION

Bid Set April 2017

IC - Applications Engineering Services 13306 - 1


SECTION 13306

INSTRUMENTATION AND CONTROLS – APPLICATIONS ENGINEERING SERVICES

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Refer to section 13300.

B. If referred to anywhere else in the project manual, Application Engineering (AE) or Applications Engineering System Supplier (AESS) services are those services specified in this Section.

C. Provide all programming, configuration, and related services required to achieve a fully integrated and operational system as specified herein. All equipment shall be controlled in full conformity with the contract drawings, process control descriptions, specifications, engineering data, instructions, and recommendations of the equipment manufacturer. Coordinate the control system for proper operation with related equipment and materials furnished by other suppliers under other Sections of these specifications and with related existing equipment.

1. Provide configuration of the PLC provided for all equipment shown on the drawings, except for controls equipment shown being provided as part of a vendor package system.

2. Provide configuration of any OIT provided.

3. Provide communication and programming modifications to the existing DWF control panel located PLC to lock-out the DWF pumps while any of the WWF pumps are running.

D. All work shall be coordinated with operating personnel to minimize impacts on daily

operation. Delays caused for any reason shall be noted and formally submitted to the Engineer and the Owner in the form of a letter.

1.2 RELATED WORK


1.3 SUBMITTALS

A. Provide all required submittals in accordance with Section 01300. The submittals listed below shall be provided as a minimum;

1. System Standards and Conventions

2. Controller Program

3. Software Maintenance documentation

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4. Operations and Maintenance Manuals

B. Supplement to Project Plan Submittal

1. Supplement the "Project Plan, Deviation List, and Schedule" submittal in Section 13300 by adding the following items to the submittal requirements: a. List of all PLC programs that will be created or modified for this project.

C. Supplement to Input/Output (I/O) List Submittal

1. Supplement the "Input/Output (I/O) List " submittal in Section 13300 by adding the following item to the submittal requirements: a. LOGICAL POINT ADDRESS: I/O address of each point.

D. System Standards and Conventions Submittal

1. Submit the standards and conventions that will be used on this project. The submittal shall define, at a minimum:

a. System naming conventions, such as tag names.

b. Alarm configuration standards, including priorities and logging

c. PLC/RTU standard programming modules, including analog input scaling, flow

totalization, equipment runtime, motor start/stop, valve open/close, and any other standard logic planned to be used.

2. To facilitate the Owner's future operation and maintenance, the submitted standards and conventions shall be used as the basis for programming and configuration of the system. System programming and configuration shall not begin prior to the System Standards and Conventions Submittal.

E. Controller Program Submittal

1. For each controller, submit the following using the controller manufacturers built in printing functions. Electronic submission of Adobe Portable Document Format ("pdf") files in lieu of paper submittals is acceptable. Review will be for general program organization, level of documentation, and overall programming standards (basic pump and valve control, for example). The review will not attempt to confirm the logic works correctly for every loop.

a. PLC programs showing ladder logic, function block, high level language or other

controller language used. Include individual rung, network, and/or command descriptions with abundant comments to clearly identify function and intent of each code segment. Each logic segment shall be clearly presented, the function of each timer described, the purpose of each subroutine call labeled and defined, etc. Program documentation shall be sufficiently clear to allow determination of compliance with the process control requirements included in the control descriptions and with the Drawings. The

Bid Set April 2017



submittal shall demonstrate that all logic provided under this project follows the same structure and format and reflects a common programming approach.

b. Submit a memory usage report for the controller. This report shall indicate

total memory capacity and unused memory capacity.

c. Submit cross reference index of I/O allocation and controller memory address. Every physical I/O point as well calculated or virtual I/O required for the implementation of the process scheme shall be included.

F. O&M Manuals - Software Maintenance Manuals

1. Include these manuals as part of Section 13300 "Final System Documentation". This required information is in addition to all requirements of Section 13300.

2. Software Listings and Databases- Submit hard copies of the same information required in the "Controller Program Submittal" except include files updated to reflect the as built system. Include PDF versions of these files in the CD specified below.

3. PID Loop Tuning Parameters - Submit annotated chart recorder traces or computer system trend screen printouts showing tuned control loop response to plus and minus 40 percent of full span step changes of loop setpoint for each individual loop. For cascade loops, submit charts showing response of the secondary loop with secondary setpoint on manual and also response of the entire cascade control loop in automatic mode. Include a description of tuning methodology used.

4. Machine Readable Documentation - Provide two sets of as built software documentation on CD-ROMs in original electronic format for all PLC and any other programs developed under this Contract. All changes made during or after testing, start-up, and commissioning shall be incorporated.

G. O&M Manuals - Operator Manuals

1. Provide Operator's Manuals prior to final acceptance of the system.

2. These manuals shall be separately bound and shall contain all information necessary for the operator to monitor and control the plant from the control system. The manuals shall be written in non-technical terms and shall be organized for quick access to each detailed description of the operator's procedure. Manuals shall contain, but not be limited to, the following information:

a. A comprehensive table of contents of the manual.

b. A simple overview of the entire system indicating the function and purpose of

each piece of equipment.

c. Step-by-step procedures for starting up or shutting down an individual component of the control system and also of the entire system.

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d. Operational description for operating peripherals including UPS, etc. Description shall include procedures for typical maintenance and troubleshooting tasks.

e. A complete glossary of terms and definition of acronyms.

f. List of personnel to be contacted for warranty and emergency services, including

name, address, telephone number, pager or cell phone number, fax number, and email address

3. Include these manuals as part of Section 13300 "Final System Documentation". This required information is in addition to all requirements of Section 13300.

1.4 MAINTENANCE


1.5 WARRANTY:

A. Refer to Section 13300 and supplement that with the requirements below.

B. All application work shall be warranted in accordance with Section 01740.

C. Provide telephone technical support within 4 hours of warranty claim. If failure cannot be resolved by telephone, provide onsite technical support within 24 hours of warranty claim.

1.6 COORDINATION MEETINGS AND WORKSHOPS

A. Refer to Section 13300. The meetings below are in addition to the meetings specified in that section.

B. Schedule and conduct a factory testing coordination meeting two weeks prior to factory testing. The purpose of this meeting is to discuss the specifics of the proposed tests and to provide a forum for coordinating the required factory testing.

C. Schedule and conduct a field-testing coordination meeting two weeks prior to field testing. The purpose of this meeting is to discuss the specifics of the proposed tests and to provide a forum for coordinating the required field-testing.


3 EXECUTION

3.1 GENERAL

A. The system specified herein shall perform the following generalized functions:

1. The system shall allow the operator to control equipment such as pumps and valves as shown on the Drawings and as defined in Section 13305 control descriptions.

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2. Perform real-time process control, including proportional integral derivative control action, sequencing, process calculations, etc.

3. Collect, calculate, and store accurate, reliable operating information for present and future uses.

4. Assist remote site operating personnel by noting and communicating off normal operating conditions and equipment failures.

5. Accumulate and store equipment running times for use in preventative maintenance.

6. Provide color graphic displays and reports for use by the system operating and supervisory personnel.

7. Provide trending for all analog values.

8. Provide control system diagnostics.

9. All process control functions including PID, calculations, sequencing, timing, etc., shall be done in the process controller.

3.2 CONTROLLER PROGRAMS

A. All applications programs shall be developed in a structured manner and shall follow an intuitive arrangement so that an instrumentation technician with basic programming knowledge will be able to understand. Programs shall utilize standard program templates or subroutines for repetitive logic such as equipment control, flow total calculations, equipment runtime calculations.

B. Make changes to the application programs and software configuration, based on comments during the submittals, the factory tests, the field tests, and during the commissioning process to meet the design intent, at no additional cost to the Owner.

3.3 TESTING


B. Supplement to Field Testing requirements

1. Loop Tuning - All PID control loops (single or cascade) shall be tuned following device installation but prior to commencement of the Functional Demonstration Test. a. Optimal loop tuning shall be achieved either by auto-tuning software or

manually by trial and error, Ziegler-Nichols step-response method, or other documented process tuning method.

b. Determine and configure optimal tuning parameters to assure stable, steady state operation of final control elements running under the control PID. Each control loop that includes anti-reset windup features shall be adjusted to provide optimum response following startup from an integral action saturation condition.

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c. Tune all PID control loops to eliminate excessive oscillating final control elements. Loop parameters shall be adjusted to achieve a decay ratio of 1 / 4 or better. In addition, loop steady state shall be achieved at least as fast as the loop response time associated with critical damping.

d. Loop performance and stability shall be verified by step changes to setpoint in the field.

e. Submit loop tuning documentation as specified in Part 1 of this Sections.

END OF SECTION

Bid Set April 2017

IC - PLC Hardware and Software 13311 - 1


SECTION 13311

PLC HARDWARE AND SOFTWARE

PART 1 GENERAL

1.1 SCOPE OF WORK

A. This Section includes Programmable logic controllers and OIT for control of process equipment, process oriented machinery, and process systems.

1.2 RELATED WORK


B. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.

C. Section 13330 Control Panels and Panel Equipment

D. Section 13335 Control Panel UPS (Single Phase)

1.3 SUBMITTALS


B. Descriptive literature, bulletins, catalog cuts and Drawings for the equipment specified herein.

C. Submit list of 3 firms that are located within 100 miles of the project site that are actively installing, programming, supporting, and maintaining the submitted PLC.

D. Complete bill of materials for the equipment.

E. Any deviation of the hardware or software systems from the preliminary submittal included in the Project Plan shall be described in detail.

F. Spare parts list.


A. ASTM D999-91: Vibration

B. (CFR) Title 47, Part 18 (European EN 55011 (formerly CISPR 11))

C. CSA Certification Class I, Division 2, Group A, B, C, D Hazardous or non-hazardous locations

D. IEC 60068-2.1 Environmental testing – Part 2-1: Tests - Test A: Cold, 2.2 Environmental testing - Part 2: Tests. Tests B: Dry heat, 2.3, 2.6 Environmental testing

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- Part 2: Tests - Test Fc: Vibration (sinusoidal) and 2.27 Environmental testing. Part 2: Tests. Test Ea and guidance: Shock

E. IEC 61000 Electromagnetic compatibility (EMC) - Testing and measurement techniques

1. Part 4-2: Electrostatic discharge immunity test

2. Part 4-3: Radiated, radio-frequency, electromagnetic field immunity test

3. Part 4-4: Electrical fast transient/burst immunity test

4. Part 4-5: Surge immunity test

5. Part 4-6: Immunity to conducted disturbances, induced by radio-frequency fields

F. IEC 61131-3: Programmable controllers - Part 3: Programming languages

G. IEC 801-3: RFI Immunity

H. IEC 801-5: Ground Continuity

I. IEC 801-2: Electrostatic Discharge

J. IEEE 472-1974/ANSI C37.90/90A-1974 (Surge Withstand) IEEE Standard for Relays and Relay Systems Associated with Electric Power Apparatus

K. MIL STD 461B CS02: RFI/EMI Susceptibility

L. NEMA Pub No ICS2-230.42: Showering Arc Test

M. NSTA Project 1A

N. UL 508 and CSA Standard C22.2 No. 142 (Isolation Voltages)


A. Manufacturer Qualifications: A qualified manufacturer shall be capable of providing training, parts, and coordination of emergency maintenance and repairs.

B. To be considered for the work under this Section, there shall be at least 3 firms located within 100 miles of the project site that have local staff actively installing, programming, supporting, and maintaining the submitted PLC for the PLC to be considered as an "or equal" to the listed manufacturers.

C. The programmable controller and all of the corresponding components within the family of controller products shall be manufactured by a company who regularly manufactures and services this type of equipment.

D. The manufacturer shall comply with ISO9001 standards for "Quality Systems- Model for Quality Assurance in Design/Development, Production, Installation, and Servicing".

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E. The manufacturer shall provide complete technical support for all of the products. This shall include factory or on-site training, regional application centers, local or factory technical assistance, and a 24/7/365 technical support phone service.


A. Deliver PLC components in packaging designed to prevent damage from static electricity and physical damage.

B. Store PLC equipment according to manufacturer requirements. At a minimum, store indoors in clean, dry space with uniform temperature to prevent condensation. Protect PLCs from exposure to dirt, fumes, water, corrosive substances, and physical damage. Also, protect the PLC from all forms of electrical and magnetic energy that could reasonably cause damage.

1.7 NOMENCLATURE AND IDENTIFICATION DEFINITIONS

A. AI: Analog Input

B. AO: Analog Output

C. Fixed I/O: A PLC style consisting of a fixed number of I/O, a processor, and a power supply all in one enclosure. Some fixed PLCs have limited expansion ability.

D. CPU: Central Processing Unit

E. DI: Discrete Input

F. DO: Discrete Output

G. I/O Input and/or Output

H. Modular: A PLC style consisting of cards that are assembled to comprise a complete unit. All I/O, CPU, and Power Supply are dedicated cards. Typically, these cards are inserted into a chassis.

I. Master/Slave: Communication between devices in which one device, the master, controls all communications. The other devices, the slaves, respond only when queried by the master. Typically used in a Remote I/O application.

J. OIT: Operator Interface Terminal

K. PID: Control action, proportional plus integral plus derivative.

L. PLC: Programmable Logic Controller

M. Remote I/O: I/O that is located remotely from the processor. Remote I/O can communicate over a variety of communication protocols and can use standard rack based I/O, or special Remote I/O hardware referred to as Distributed I/O.

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N. SCADA: Supervisory Control and Data Acquisition

1.8 SPARE I/O

A. Each I/O drop and I/O location shall include at least 20 percent (minimum of four) points of each type (AI, AO, DI, and DO) for future use, regardless of whether any of those point types are used in that drop or location or not. The spares shall be the same type of I/O modules supplied.

B. Spare output points that require the use of an external relay shall be supplied with the external relay.

C. Regardless of the spare requirement, all installed unused points on all I/O modules shall be wired to terminal blocks in the order that they occur on the I/O modules. Unwired spares shall not be acceptable.

1.9 MANUFACTURER SUPPORT

A. Provide a written proposal for a manufacturer support agreement for products specified herein for a minimum of 12 months starting at final completion of the project. The cost of this manufacturer support agreement shall not be included in the Contract Price. The support agreement shall be executed in the name of, and for the benefit of, the Owner. At a minimum, this agreement shall provide the Owner with:

1. 8 AM to 5 PM, 5 day per week manufacturer telephone support

2. Access to the manufacturer's technical support website

3. Software and firmware updates.

PART 2 PRODUCTS

2.1 GENERAL

A. Provide Programmable Logic Controller equipment with the required memory and functional capacity to perform the specified sequence of operation with the scheduled input and output points.

B. Processor Systems shall include processor, power supply, input/output modules, communication modules, redundancy modules, and remote interface modules as required to meet system requirements.

C. Furnish products listed and classified by Underwriters Laboratories (UL), CSA, or FM approval as suitable for purpose specified and indicated.

D. All equipment and devices furnished hereunder shall be designed for continuous industrial service. The system shall contain products of a single manufacturer, insofar as possible, and shall consist of equipment models that are currently in production.

E. All equipment furnished shall be designed and constructed so that in the event of power interruption the systems shall go through an orderly shutdown with no loss of

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memory, and resume normal operation without manually resetting when power is restored.

F. The PLCs shall communicate between the OIT and field-mounted transducers, switches, controllers, and process actuators.

G. The PLC shall be capable of stand-alone operation.

H. Agency and environmental specifications:

1. Electrical supply voltage to the PLC shall be 120 Vac, plus or minus "15 percent, 48-63Hz. PLC system power supplies shall be fused for overload protection.

2. Vibration: 3.5 mm Peak-to-Peak, 5-9 Hz: 1.0G, 9-150\Hz. The method of testing is to be based upon IEC 68-2-6 and JIS C 0911 standards for vibration. The system is to be operational during and after testing. Vibration Rating of 2.0G maximum peak acceleration for 10 to 500Hz. in accordance with at least one of the following:

a. Installed rating: DIN rail mounted PLC: 10-57 Hz, amplitude 0.075 mm,

acceleration 25-100 Hz, and

b. Panel or plate mounted PLC: 2-25 Hz, amplitude 1.6mm, acceleration 25-200 Hz.

c. In compliance with IEC 60068 and IEC 61131.

3. Shock: 15G, 11 msec. The method of testing is to be based upon IEC 68-2-27 and JIS C 0912 standards for shock. The system is to be operational during and after testing.

4. Temperature: All PLC hardware shall operate at an ambient temperature of 0 to +60 degrees C, with a storage ambient temperature rating of -40 to +85 degrees C.

5. Relative Humidity: The Programmable Controller hardware shall function continuously in the relative humidity range of 5 percent to 95 percent non- condensing.

6. Noise Immunity: The Programmable Controller system shall be designed and tested to operate in the high electrical noise environment of an industrial plant as governed by the following regulations: IEEE 472, IEC 801, MILSTD 461B, IEC 255-4, NEMA ICS 2-230.40, and ANSI/IEEE C-37.90A-1978.

7. Altitude:

a. Operation: 0-6,500 feet

b. Storage: 0-9,800 feet

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8. Degree of protection: NEMA 1 (IP20)

9. All products shall have corrosion protection.

I. All major assemblies and sub-assemblies, circuit boards, and devices shall be identified using permanent labels or markings indicating:

1. Modules product type such as analog or digital

2. Modules catalog number

3. Modules major revision number

4. Modules minor revision number

5. Module manufacturer vendor

6. Module serial number

J. All necessary cables shall be included. All cables and connectors shall be as specified by the manufacturer. Cables shall be assembled and installed per the manufacturer recommendations.

K. MANUFACTURERS

1. Provide all PLCs from a single manufacturer. If the PLC manufacturer has authorized third party vendors to provide modules that are compatible with their platforms, then products manufactured by these authorized third party vendors will be acceptable.

2. Provide the PLC system by one of the following: a. Rockwell Automation Allen Bradley MicroLogix

L. Central Processing Unit (CPU)

1. The CPU shall be, at a minimum, a 16-bit microprocessor that provides system timing and is responsible for scheduling I/O updates, with no user programming required to ensure discrete or analog update. It shall execute user relay ladder logic programs, communicate with intelligent I/O modules, and perform on-line diagnostics. The CPU shall consist of a single module which solves application logic, stores the application program, stores numerical values related to the application processes and logic, and interfaces to the I/O.

2. The CPU shall sample all the discrete and analog inputs and outputs including internal coils and registers, and service special function modules every scan. The CPU shall process the I/O with user program(s) stored in memory, then control the outputs based on the results of the logic operation.

3. Supply the CPU with a battery-backed time of day clock and calendar.

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4. The CPU family shall allow for user program transportability from one CPU model to another.

M. Diagnostics

1. The CPU shall perform on-line diagnostics that monitor the internal operation of the PLC. If a failure is detected, the CPU shall initiate system shutdown and fail- over. The following, at a minimum, shall be monitored: Memory failure, memory battery low, and general fault, communications port failure, scan time over run, I/O failure, and analog or special function I/O module failure.

2. All diagnostic information shall be accessible to the host communications interfaces and to the PLC program.

3. The PLC shall have indicators and on board status area to indicate the following conditions:

a. CPU run

b. CPU error or fault

c. I/O failure or configuration fault.

d. Status of Battery or back-up power module

e. Communications indicator

N. Memory

1. The user program and data shall be contained in non-volatile battery backed memory of type CMOS RAM program memory or equivalent.

2. Memory Backup System: provide lithium battery backup or equivalent capable of retaining all memory for a minimum of three months and a Flash memory system capable of reloading program in the event of memory loss.

a. Backup Storage: The backup battery or module shall be capable of being

replaced without disrupting memory integrity. Provide a visual indication of low battery voltage or module error and an alarm bit in the PLC program.

b. Flash or SD Memory Card: Memory card storage capacity shall be equal to or

greater than processor memory capacity. Memory cards shall be installed in processors for factory testing.

3. The operating system shall be contained in non-volatile firmware. The memory containing the operating system shall be field updateable via a separate update tool.

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O. Programming Environment

1. Programming port: The PLC shall utilize a serial USB or Ethernet port for programming.

2. On-Line programming: Application programs may be modified or stored while the CPU is running, with minimal impact on the scan time.

3. Online programming including runtime editing

4. IEC 61131-3 programming languages supported: Ladder logic, function block, sequential function chart, and structure text.

5. Supply all hardware and software necessary to program the CPU in these languages.

P. Communication Ports

1. The CPU shall be expandable and supplied with additional modules to support the required communication interfaces.

2.2 POWER SUPPLIES

A. The PLC shall have chassis mounted power supplies to power the chassis backplane, and provide power for the processor and applicable modules.

B. Power supplies shall have a clearly visible LED to indicate that the incoming power is acceptable and the output voltage is present.

C. Power supplies shall feature over-current and over-voltage protection and should be designed to operate in most industrial environments without the need for isolation transformers.

D. Power supplies shall be sized to accommodate the anticipated load plus 30%.

E. DC power supplies shall be capable of handling ripple up to 2.4V peak to peak.

F. AC Line Voltage rating of 85 to 265Vac, 47-63Hz

G. The power supplies shall allow for brown outs of at least 1/2 of a cycle, a harmonic rate of 10%, and will sustain continuous operation through momentary interruptions of AC line voltage of 10ms or less.

H. Automatically shut down the Programmable Controller system whenever its output power is detected as exceeding 125% of its rated power

I. Provide surge protection, isolation, and outage carry-over up to 2 cycles of the AC line

J. Redundant power supplies will comply with all the requirements of non-redundant power supplies in addition to the features stated below.

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1. The redundant power supplies shall be designed to share the current required by the chassis. In the event of a failure of one redundant power supply, the remaining supply will accommodate the entire load of the chassis without disruption to the chassis activity.

2. Provide a failsafe fuse that is not accessible by the customer

3. Provide a solid-state relay connection to allow for failure annunciation when wired to an input module

4. Diagnostic LED status indicators for Power and redundancy

2.3 CHASSIS

A. PLC shall be chassis based.

B. All system and signal power to the CPU and support modules shall be distributed on the backplane. No interconnecting wiring between these modules via plug-terminated jumpers shall be acceptable.

C. All system modules, main and expansion chassis shall be designed to provide for free air flow convection cooling. No internal fans or other means of cooling, except heat sinks, shall be permitted.

D. All system modules including the processor shall be removable from the chassis or inserted in to the chassis while power is being supplied to the chassis without faulting the processor or damaging the modules.

E. Modules shall be designed to plug into a chassis and to be keyed to allow installation in only one direction. The design must prohibit upside down insertion of the modules as well as safeguard against the insertion of a module into the wrong slot or chassis via an electronic method for identifying a module. Electronic keying shall perform an electronic check to ensure that the physical module is consistent with what was configured.

2.4 DISCRETE INPUT AND OUTPUT MODULES

A. General

1. Digital input and output modules shall provide ON/OFF detection and actuation.

2. The I/O count and type shall be as required to implement the functions specified plus an allowance for active spares, as noted below.

3. Modules shall be designed to be installed or removed while chassis power is applied.

4. Modules shall have indicators to display the status of communication, module health and input / output devices.

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5. Each module shall have the following status indicators.

a. The On/Off state of the field device.

b. The module's communication status.

B. Module Specifications (120VAC Input Module)

1. Nominal Input Voltage of 120VACc

2. On-State Current of 15mA @132V AC, 47-63Hz maximum

3. Maximum Off-State Voltage of 20V

4. Maximum Off-State Current of 2.5mA

5. Number of Points per Card: 16

2.5 ANALOG INPUT AND OUTPUT MODULES

A. General

1. Analog input modules shall convert an analog signal that is connected to the module's screw terminals into a digital value. The digital value representing the magnitude of the analog signal shall be transmitted on the backplane. Analog output modules shall convert a digital value that is delivered to the module via the backplane into an analog signal on the module's screw terminals.

2. Modules shall be designed to be installed or removed while chassis power is applied.

3. Modules shall have indicators to display the status of communication, module health and input / output devices.

4. Each analog module shall provide both hardware and software indication when a module fault has occurred. Each module shall have an LED fault indicator and the programming software shall display the fault information.

5. Analog modules shall be software configurable through the I/O configuration portion of the programming software.

6. The following status shall be capable of being examined in ladder logic

a. Module Fault Word – Provides fault summary reporting.

b. Channel Fault Word – Provides under-range, over-range and communications fault reporting.

c. Channel Status Words – Provides individual channel under-range and over- range fault reporting for process alarm, rate alarms and calibration faults.

7. The 24 VDC power for analog instrument loops shall be provided as a part of the system. The 24 VDC power supply shall be derived from the 120 VAC input power

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circuit to the PLC. The field side of the 24 VDC power sources(s) shall have individual or grouped (of logically associated circuits) fusing and be provided with a readily visible, labeled blown fuse indicator.

B. Isolated Analog Output Current Module

1. Output Current Range of 4 to 20 mA

2. Current Resolution of 12 bits across 20 mA

3. Open Circuit Detection - None

4. Output Overvoltage Protection - 24V ac/dc maximum

5. Output Short Circuit Protection - 20 mA or less (electronically limited)

6. Calibration Accuracy - Better than 0.1% of range from 4mA to 20 mA

7. Calibration Interval - 12 months typical

8. Number of Points per Card: 4

2.6 COMMUNICATION INTERFACES

A. The PLC shall be capable of the following communication protocols:

1. Modbus (RTU and ASCII) for up to 247 slaves

B. When required provide a Communications Interface Module mounted in the chassis or the equivalent port directly on the CPU.

2.7 PLC SOFTWARE

A. Provide a PLC configuration and application development software package complete with documentation and disks. The PLC software package and associated licensing and/or activation shall be installed on the computers shown on the Drawings.

B. The software package shall allow on-line/off-line program development, annotation,

monitoring, debugging, uploading, and downloading of programs to the PLCs.

C. All required hardware (including cables, cable adapters, etc.) for connection to PLCs shall be furnished.

D. All software licenses required to achieve the functionality described in the Specifications shall be provided.

E. The software package shall include a software license agreement allowing the Owner the right to use the software as required for any current or future modification, documentation, or development of the PLCs furnished for this project.

F. The software provided shall be capable of the following IEC 61131-3 functions:

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1. Ladder logic.

2. Function block.

3. Sequential function chart.

4. Structure text.

G. In addition to the above editors, an add-on instruction editor shall work with any of the above-mentioned editors to create custom reusable function blocks. This software shall allow any of the derived function blocks to be modified on-line.

H. The software shall be Microsoft Windows-based and run on the supplied computers.

I. The software shall include a security feature to prevent unauthorized personnel from modifying and downloading the programs.

J. Provide an I/O simulator which allows the PLC application load program to be tested on a PC with simulated analog and digital inputs and outputs, allowing I/O testing and debugging to be performed in a safe, isolated environment without the need for running the PLC CPU and process I/O boards.

2.8 OPERATOR INTERFACE TERMINAL (OIT)

A. OITs shall be mounted on the control panel.

B. Manufacturers:

1. Provide operator interface terminals (OIT) from one of the following:

a. Allen-Bradley.

b. Or equal.

2. Software:

a. Operator Interface Terminal shall be pre-packaged with all configuration and programming software necessary to perform functions as shown on drawings and within the specifications.

b. Integrated OIT software shall have the following features:

1) Trending. 2) Data Logging. 3) Alarms. 4) Graphic Symbols. 5) Animations.

C. I/O Ports and Devices:

1. OIT shall have a minimum of one Ethernet 10/100 Mbps for connectivity or programming.

2. OIT shall have a minimum of one Serial RS232 port.

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3. OIT shall have a minimum of one Type 2 USB port.

D. Display:

1. OIT display size shall be minimum10".

2. Type of display for the OIT shall be Color Active Matrix TFT.

3. Display shall support touch screen input.

E. Environmental:

1. Rating: OIT shall be rated to maintain the rating of the control panel it will be mounted in.

2. Temperature: Operating temperature range of the OIT shall range 0 - 50 °C.

2.9 SPARE PARTS

A. General requirements for spare parts are specified in section 13300.

B. The following PLC spare parts shall be furnished

1. Processors: Provide spare processor unit(s) for each unique processor installed.

2. Memory Cards: Provide spares for each type of card installed.

3. I/O Cards: Provide spares for each unique I/O module type installed. Provide two or 10 percent of installed quantity, whichever is greater.

4. Communication modules: Provide one spare communication module for each unique communication module installed.

5. PLC Power supplies: Provide spare power supplies for each unique power supply installed.

6. Chassis: Provide spare chassis for each unique chassis installed.

7. Fixed PLCs: Provide spares for each unique type of PLC installed.

8. Miscellaneous components (including cables): Provide spares for each unique component installed.

PART 3 EXECUTION

3.1 GENERAL INSTALLATION

A. Maintain area free of dirt and dust during and after installation of programmable controller products.

B. Anchor PLCs within enclosures as recommended by the PLC manufacturer.

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C. Ventilation slots shall not be blocked, or obstructed by any means.

D. Examine areas, surfaces, and substrates to receive PLCs for compliance with requirements, installation tolerances, and other conditions affecting performance. Proceed with installation only after unsatisfactory conditions have been corrected.

E. Install in accordance with manufacturer's instructions.

F. Unload, unpack and transport equipment to prevent damage or loss.

G. Replace damaged components as directed by Engineer.

3.2 PANEL LAYOUT

A. Coordinate size and configuration of enclosure to meet project requirements. Drawings indicate maximum dimensions for PLCs, minimum clearances between PLCs, and adjacent surfaces and other items.

B. Comply with indicated maximum dimensions and clearances, or with PLC vendors required distances if they are greater than the distances indicated.

1. Provide spacing around PLC as required by the PLC manufacturer to ensure adequate cooling. Insure that the air surrounding the PLC has been conditioned to maintain the required temperature and humidity range.

2. Wires entering and exiting PLC components shall be sized to comply with the PLC manufacturers requirements. Doors on all components shall be able to be fully closed when all the wires are installed.

3. For chassis mounted PLCs, no wiring, wire ducts, or other devices shall obstruct the removal of cards from the rack.

4. PLC lights, keys, communication ports, and memory card slots shall be accessible at all times. Lights shall be visible at all times when enclosure door is opened.

C. Control panel designer shall provide independent line fuses or circuit breakers, per the PLC manufacturer recommendation, for each power supply, input module, output module, and other modules with separately derived power requirements.

D. Control panel designer shall insure that communication signals, 4-20mA signals (including those with embedded HART), are properly conditioned for the PLC and protected from all sources of radiated energy or harmonics.

E. Each PLC (including all I/O) shall be powered from the UPS power conditioning system in

Section 13335.

F. Where multiple sets of mechanical equipment are provided for process redundancy, arrange their field connections to I/O modules so that the failure of a single I/O module will not disable the redundant system. This applies to all I/O types. The acceptability of the I/O arrangement shall be at the discretion of the engineer.

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G. Provide all required cables, cords, and connective devices for interface with other control system components.

END OF SECTION

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Bid Set April 2017

IC - Control Panels Enclosures and Panel Equipment 13330 - 1


SECTION 13330

INSTRUMENTATION AND CONTROLS - CONTROL PANELS AND PANEL MOUNTED EQUIPMENT

PART 1 GENERAL

1.1 SCOPE OF WORK


B. Furnish and install control panels and panel mounted equipment as specified herein and shown on the Drawings.

C. All new panels and panel components shall match existing equipment makes and models wherever possible, so that system additions can be most easily integrated with respect to operation and maintenance training, spare parts inventory, and service contracts. Even when exact matches are not possible, equipment furnished must be fully compatible with the existing system. Color, size, and material of new panels should conform to that of existing panels.

D. Each panel shall be supplied with full sub-panels with the minimum specified dimensions regardless of the quantity of mounted components inside the panel. All panel mounted components shall be mounted on the single rear-of-panel sub-panel unless the density of devices exceeds the panel mounting space permitted by the minimum panel dimensions specified. Side panel mounted components shall only be permitted after review and approval of the Engineer.

E. Furnish the following panels.

PANEL SCHEDULE Panel Designation Minimum

Panel Size Maximum Space Available

Enclosure Rating & Type

PLC Enclosure (CP-1)

60-inch high by 72-inch wide by 24- inch deep

90-inch high by 72-inch wide by 24-inch deep

NEMA Type 4X 316-SS, 2- door, steel construction, free standing. Front Access Only

1.02 RELATED WORK


1.03

SUBMITTALS


B. Descriptive literature, bulletins, catalog cuts and Drawings for the equipment specified

herein.

C. Complete bill of materials for the equipment.

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D. Spare parts list.

E. Panel Layout Drawings and Wiring Diagrams Submittal

1. Where direct hardwired interfaces exist between the PCSS control panels and vendor provided control panels furnished under other Divisions, the Contractor shall provide to the PCSS the approved submittals in order for the PCSS to provide complete wiring diagrams showing all wiring connections in the I/O system. This includes but is not limited to terminal block numbering, relay contact information, instruments, equipment, and control panel names. These drawings shall be included in the Final O&M submittal. Leaving this information blank on the Final Documentation drawings is not acceptable.

2. Panel Layout Drawings: Drawings shall be furnished for all panels, consoles, and equipment enclosures specified. Panel assembly and elevation drawings shall be drawn to scale and detail all equipment in or on the panel. Panel drawings shall be 11"x17" in size. At a minimum, the panel drawings shall include the following:

a. Interior and exterior panel elevation drawings to scale.

b. Nameplate schedule.

c. Conduit access locations.

d. Panel construction details.

e. Cabinet assembly and layout drawings to scale. The assembly drawing shall

include a bill of material on the drawing with each panel component clearly defined. The bill of material shall be cross-referenced to the assembly drawing so that a non-technical person can readily identify all components of the assembly by manufacturer and model number.

f. Fabrication and painting specifications including color (or color samples).

g. Construction details, NEMA ratings, intrinsically safe barrier information, gas

sealing recommendations, purging system details, etc. for panels located in hazardous locations or interfacing to equipment located in hazardous areas.

h. For every control panel, heating and cooling calculations for each panel

supplied indicating conformance with cooling requirements of the supplied equipment and environmental conditions. Calculations shall include the recommended type of equipment required for both heating and cooling.

i. Submit evidence that all control panels shall be constructed in conformance

with UL 508 and bear the UL seal confirming the construction. Specify if UL compliance and seal application shall be accomplished at the fabrication location or by field inspection by UL inspectors. All costs associated with obtaining the UL seal and any inspections shall be borne by the Contractor.

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3. Panel Wiring Diagrams: Panel wiring diagrams depicting wiring within and on the panel as well as connections to external devices. If ISA Loop Wiring Diagrams are specified below, equipment external to the control panel and related external connections do not need to be shown on the Panel Wiring Diagrams. Panel wiring diagrams shall include power and signal connections, UPS and normal power sources, all panel ancillary equipment, protective devices, wiring and wire numbers, and terminal blocks and numbering. Field device wiring shall include the device ISA-tag and a unique numeric identifier. The diagrams shall identify all device terminal points that the system connects to, including terminal points where I/O wiring lands on equipment not supplied by the PCSS. Wiring labeling used on the drawings shall match that shown on the Contract Documents or as developed by the PCSS and approved by the Engineer. I/O wiring shall be numbered with rack number, slot number, and point number. Two-wire and four-wire equipment shall be clearly identified and power sources noted. Submit final wire numbering scheme. Panel drawings shall be 11" x17" in size.

4. ISA Loop Wiring Diagrams: Not required

1.4 COORDINATION MEETINGS








1.8 NOMENCLATURE AND IDENTIFICATION


1.9 MAINTENANCE


B. Test Equipment:

1. Refer to Section 13300.

1.10 WARRANTY


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PART 2 PRODUCTS

2.1 GENERAL


2.2 LIGHTNING/SURGE PROTECTION


2.3 CONTROL PANEL GENERAL REQUIREMENTS

A. The dimensions within this Section and on the Contract Drawings are for general reference only. Ensure that final enclosure sizing and panel arrangements accommodate all required equipment for a fully integrated and operational system as specified herein and in the Contract Documents.

B. Each control panel and terminal cabinet shall bear the UL label. The UL label shall apply to the enclosure, the specific equipment supplied with the enclosure, and the installation and wiring of the equipment within and on the enclosure. If required for UL labeling, provide ground fault protective devices, isolation transformers, fuses and any other equipment necessary to achieve compliance with UL 508 requirement. The Drawings do not detail all UL 508 requirements.

C. All panel doors shall have a lock installed in the door handle, or a hasp and staple for padlocking. Locks for all panels provided under this Contract shall be keyed alike.

D. The devices designated for rear-of-panel mounting shall be arranged within the panel according to respective panel drawings and in a manner to allow for ease of maintenance and adjustment. Heat generating devices such as power supplies shall be located at or near the top of the panel.

E. The panels shall be completely fabricated, instruments and devices installed and wired at the PCSS's facility.

F. All components shall be mounted in a manner that shall permit servicing, adjustment, testing, and removal without disconnecting, moving, or removing any other component. Components mounted on the inside of panels shall be mounted on removable plates and not directly to the enclosure. Mounting shall be rigid and stable unless shock mounting is required otherwise by the manufacturer to protect equipment from vibration. Component mounting shall be oriented in accordance with manufacturer's recommendations. The internal components shall be identified with suitable plastic or metal engraved nametags mounted adjacent to (not on) each component identifying the component in accordance with the drawing, specifications, and PCSS's data.

G. All exterior panel mounted equipment shall be installed with suitable gaskets, faceplates, etc. required to maintain the NEMA rating of the panel.

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H. Nameplates

1. All panels and panel devices shall be supplied with suitable nameplates, which identify the panel and individual devices as required. Unless otherwise indicated, each device nameplate shall include up to three lines with the first line containing the device tag number as shown on the drawings, the second line containing a functional description (e.g., Recirculation Pump No. 1), and the third line containing a functional control description (e.g., Start).

2. Unless escutcheon plates are specified or unless otherwise noted on the Drawings, nameplates shall be 3/32-inch thick, black and white, Lamicoid with engraved inscriptions. The letters shall be Black against a White background unless otherwise noted. Edges of the nameplates shall be beveled and smooth. Nameplates with chipped or rough edges will not be acceptable.

3. Nameplate fasteners and mounting shall be epoxy adhesive or stainless steel screws for cabinet mounted nameplates

4. For every panel, provide a panel nameplate with a minimum of 1-in high letters. Provide legend plates or 1-in by 3-in engraved nameplates with 1/4-in lettering for identification of door mounted control devices, pilot lights, and meters.

5. Single lamicoid nameplates with multiple legends shall be used for grouping of devices such as selector switches and pilot lights that relate to one function.

I. Mounting Elevations

1. ISA Recommended Practice RP60.3 shall be used as a guide in layout and arrangement of panels and panel mounted components. Dimensions shall account for all housekeeping pads that panels will sit on once they are installed.

2. Centerline of indicators and controllers shall be located no lower than 48-inches or higher than 66-inches above the floor on a panel face.

3. Centerline of lights, selector switches, and pushbuttons shall be located no lower than 32-inches or higher than 70-inches above the floor on a panel face.

4. Tops of annunciators shall be located no higher than 86-inches above the floor on a panel face.

5. Installation of panel components shall conform to component manufacturers'

guidelines.

2.4 PANEL MATERIALS AND CONSTRUCTION

A. Structure and Enclosure

1. Panels shall be of continuous welded-steel or FRP construction as shown on the Panel Schedule. Provide angle stiffeners as required on the back of the panel face to prevent panel deflection under instrument loading or operation. Internally the panels shall be supplied with a structural framework for instrument support

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purposes and panel bracing. The internal framework shall permit panel lifting without racking or distortion. Provide removable lifting rings designed to facilitate simple, safe rigging, and lifting of the control panels during installation.

2. Each panel shall be provided with full height, fully gasketed access doors where shown. Doors shall be provided with a three-point stainless steel latch and heavy duty stainless steel locking handle. Panel access doors shall be provided with full length, continuous, piano type stainless steel hinges with stainless steel pins. Front access doors with mounted instruments or control devices shall be of sufficient width to permit door opening without interference from flush mounted instruments.

3. The panels, including component parts, shall be free from sharp edges and welding flaws. Wiring shall be free from kinks and sharp bends and shall be routed for easy access to other components for maintenance and inspection purposes.

4. The panel shall be suitable for top and bottom conduit entry as required by the Electrical Drawings. For top mounted conduit entry, the panel top shall be provided with nominal one-foot square removable access plates, which may be drilled to accommodate conduit and cable penetrations. All conduit and cable penetrations shall be provided with ground bushings, hubs, gasketed locknuts, and other accessories as required to maintain the NEMA rating of the panel and electrical rating of the conduit system.

5. All panels shall be considered to be in outdoor environments and shall be rated NEMA 4X unless otherwise noted. All panels located in a hazardous location shall be rated for the type of hazard (e.g., NEMA 7 for Class 1, Division 1).

B. Freestanding and Floor-Mounted Vertical Panels

1. Freestanding and floor-mounted vertical panels shall meet the NEMA classification as shown on the drawings or specified herein. The panels shall be constructed of 12-gauge sheet steel, suitably braced internally for structural rigidity and strength. All NEMA 4X rated panels shall be constructed of Type 316 stainless steel. Front panels or panels containing instruments shall be not less than 10-gauge stretcher leveled sheet steel, reinforced to prevent warping or distortion.

C. Finish Requirements

1. All sections shall be descaled, degreased, filled, ground and finished. The enclosure when fabricated of steel shall be finished with two rust resistant phosphate prime coats and two coats of enamel, polyurethane, or lacquer finish which shall be applied by either the hot air spray or conventional cold spray methods. Brushed anodized aluminum, stainless steel, and FRP panels will not require a paint finish.

2. The panels shall have edges ground smooth and shall be sandblasted and then cleaned with a solvent. Surface voids shall be filled and ground smooth.

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3. Immediately after cleaning, one coat of a rust-inhibiting primer shall be applied inside and outside, followed by an exterior intermediate and top coat of a two- component type epoxy enamel. A final sand-ing shall be applied to the intermediate exterior coat before top coating.

4. Apply a minimum of two coats of manufacturer’s standard, flat light-colored

lacquer, on the panel interior after priming.

5. Unless otherwise noted, the finish exterior colors shall be ANSI 61 gray with a textured finish.

D. Print storage pockets shall be provided on the inside of each panel. The storage pockets shall be steel, welded on to the door, and finished to match the interior panel color. The storage pocket shall be sufficient to hold all of the prints required to service the equipment, and to accommodate 8.5 inch by 11 inch documents without folding.

E. Where specified on the Panel Schedule, a folding shelf shall be provided on the inside of the door on all free-standing and floor-mounted panels. The shelf shall be suitable for a laptop computer and shall be placed such that an open laptop computer does not interfere with any door-mounted devices. The folded shelf shall not interfere with any internal panel components when the door is closed. The folding shelf shall automatically lock in the horizontal position when raised. The folding shelf shall be approximately 18 inches wide by 12 inches deep and shall have a minimum distributed load rating of 100 pounds. All parts shall be made of heavy gauge steel and shall be painted white or finished to match the interior panel color.

2.5 ENVIRONMENTAL CONTROL

A. All panels shall be provided with louvers, sun shields, heat sinks, forced air ventilation, or air conditioning units as required to prevent temperature buildup inside of panel. The internal temperature of all panels shall be regulated to a range of 45 Deg F to 104 Deg F under all conditions. Under no circumstances shall the panel cooling or heating equipment compromise the NEMA rating of the panel.

B. Except for panels mounted with their backs directly adjacent to a wall, louvers shall be in the rear of the panels, top and bottom, and shall be stamped sheet metal construction.

C. For panels mounted with their backs directly adjacent to a wall, louvers shall be on the sides.

D. Forced air ventilation fans, where used, shall provide a positive internal pressure within the panel, and shall be provided with washable or replaceable filters. Fan motors shall operate on 120-volt, 60-Hz power.

E. For panels with internal heat that cannot be adequately dissipated with natural convection and heat sinks, or forced air ventilation, an air conditioner shall be provided.

F. Provide custom fabricated sun shields for all outdoor panels in accordance with the following requirements:

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1. Sun shields shall be fabricated from minimum 12-gauge Type 316 stainless steel. Units shall be designed, fabricated, installed, and supported to fully cover and shade the top, sides and back of the enclosure, and to partially shade the front panel of the enclosure, from direct exposure to sunlight from sunrise to sunset.

2. Depending on overall size, sun shields may be fabricated in single or multiple

segments for attachment to the enclosure support framing or to separate free standing framing around the enclosure.

3. Sun shields shall not be attached directly to the enclosure by drilling holes through, or welding studs to, the enclosure surfaces, and shall be designed and mounted to provide a minimum 3-inch air gap all around the enclosure for air circulation and heat dissipation.

4. The top section of all sun shields shall be sloped at a minimum angle of 5 degrees from horizontal. For wall mounted enclosures, the top section shall slope downward away from the wall and towards the front of the enclosure. For free standing, floor mounted and frame mounted enclosures the top section shall slope downward towards the back side of the enclosure.

5. The front edge of the top section of all sun shields shall incorporate a narrow and

more steeply sloped drip shield segment which sheds water away from the front of the enclosure and prevents it from dripping or running directly onto the front panel of the enclosure.

6. All seam welds used in sun shield fabrication shall be continuous and shall be ground smooth.

7. All exposed corners, edges and projections shall be smooth rounded or chamfered to prevent injury.

G. All outdoor enclosures and enclosures located in unheated areas indoors or in areas subject to humidity and moisture shall be provided with an integral heater, fan, and adjustable thermostat to reduce condensation and maintain the minimum internal panel temperature. Mount the unit near the bottom of the enclosure with discharge away from heat-sensitive equipment. Heater shall be Hoffman DAH 100 Watts, 115 Volt, 50/60 HZ or equal.

2.6 CORROSION CONTROL

A. Panels shall be protected from internal corrosion by the use of corrosion-inhibiting vapor capsules as manufactured by Northern Technologies International Corporation, Model Zerust VC; Hoffman Model AHCI; or equal.

2.7 CONTROL PANEL - INTERNAL CONSTRUCTION

A. Internal Electrical Wiring

1. All interconnecting wiring shall be stranded, type MTW, and shall have 600-volt insulation and be rated for not less than 90 degrees Celsius. Wiring for systems operating at voltages in excess of 120 VAC shall be segregated from other panel

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wiring either in a separate section of a multi-section panel or behind a removable Plexiglas or similar dielectric barrier. Panel layout shall be developed such that technicians shall have complete access to 120 VAC and lower voltage wiring systems without direct exposure to higher voltages.

2. Power distribution wiring on the line side of fuses or breakers shall be 12 AWG

minimum. Control wiring on the secondary side of fuses shall be 16 AWG minimum. Electronic analog circuits shall utilize 18 AWG shielded, twisted pair, cable insulated for not less than 600 volts.

3. Power and low voltage DC wiring systems shall be routed in separate wireways. Crossing of different system wires shall be at right angles. Different system wires routed parallel to each other shall be separated by at least 6-inches. Different wiring systems shall terminate on separate terminal blocks. Wiring troughs shall not be filled to more than 60 percent visible fill.

4. Terminations

a. All wiring shall terminate onto single tier terminal blocks, where each terminal is uniquely and sequentially numbered. Direct wiring between field equipment and panel components is not acceptable.

b. Multi-level terminal blocks or strips are not acceptable unless they are

approved by the Engineer in advance of panel wiring diagrams. If approved, they shall be mounted on angled din rail elevated from the back panel.

c. Terminal blocks shall be arranged in vertical rows and separated into groups

(power, AC control, DC signal). Each group of terminal blocks shall have a minimum of 25 percent spares.

d. Terminal blocks shall be the compression type, fused, unfused, or switched as

shown on the Contract Drawings or specified elsewhere in Division (13) (40).

e. Discrete inputs and outputs (DI and DO) shall have two terminals per point with adjacent terminal assignments. All active and spare PLC and controller points shall be wired to terminal blocks.

f. Analog inputs and outputs (AI and AO) shall have three terminals per shielded

pair connection with adjacent terminal assignments for each point. The third terminal is for shielded ground connection for cable pairs. Ground the shielded signal cable at the PLC cabinet. All active and spare PLC and controller points shall be wired to terminal blocks.

g. Wire and tube markers shall be the sleeve type with heat impressed letters

and numbers.

h. Only one side of a terminal block row shall be used for internal wiring. The field wiring side of the terminal shall not be within 6-inches of the side panel or adjacent terminal or within 8-inches of the bottom of free standing panels, or within 3-inches of stanchion mounted panels, or 3-inches of adjacent wireway.

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i. Circuit power from the SCADA cabinet out to field devices (switches, dry contacts etc.) that are used as discrete inputs to the PLC input cards shall be isolated with an isolating switch terminal block with flip cover that is supplied with a dummy fuse. Isolation switch block shall be an Allen Bradley Model 1492-H7 or equal. One isolating switch terminal block per loop numbered piece of equipment and one per spare I/O point is acceptable.

j. All PLC discrete outputs to the field shall be isolated with an isolating fuse switch

terminal block with a flip cover and a neon blown fuse indicator. The single circuit fusible terminal block shall be an Allen Bradley 1492-H4 or equal.

5. All wiring to hand switches and other devices, which are live circuits independent of the panel's normal circuit breaker protection, shall be clearly identified as such.

6. All wiring shall be clearly tagged and color coded. All tag numbers and color coding shall correspond to the panel wiring diagrams and loop drawings prepared by the PCSS. All power wiring, control wiring, grounding, and DC wiring shall utilize different color insulation for each wiring system used. The color coding scheme shall be:

a. Incoming 480Y/277 VAC 3-Phase, 4-wire:

1) Phase A-Orange 2) Phase B-Brown 3) Phase C-yellow 4) Neutral-White

b. 120 VAC Hot wiring downstream of panel circuit breaker – Red

c. 120 VAC Hot wiring derived from a UPS system – Red with Black stripe

d. Three phase power – Brown, Orange, Yellow, and Green ground or as

specified in Division 16.

e. 120 VAC neutral - White

f. Ground - Green

g. DC power or control wiring – Blue

h. DC analog signal wiring – Black (+), White (-)

i. Foreign voltage – Yellow

7. Provide surge protectors on all incoming power supply lines at each panel per the requirements of Section 13300.

8. Each field instrument furnished under Division 13 and shown on the Drawings as deriving input power from the control panel(s) shall have a separate power distribution circuit with a circuit breaker or fuse and blown fuse indication. All

Bid Set April 2017



instruments requiring 120VAC power shall be powered from the UPS source in the panel where the instrument signals lands.

9. Wiring trough for supporting internal wiring shall be plastic type with snap-on covers. The side walls shall be open top type to permit wire changing without disconnecting. Trough shall be supported to the subpanel by stainless steel screws. Trough shall not be bonded to the panel with glue or adhesives.

10. Each panel shall have a single tube, fluorescent light fixture, 20 Watt in size, mounted internally to the ceiling of the panel. Light fixture shall be switched and shall be complete with the lamp.

11. Each panel shall have a specification grade duplex convenience receptacle with ground fault interrupter, mounted internally within a stamped steel device box with appropriate cover. Convenience receptacle shall not be powered from a UPS and shall be protected by a dedicated fuse or circuit breaker.

12. Each panel shall be provided with an isolated copper grounding bus for all signal and shield ground connections. Shield grounding shall be in accordance with the instrumentation manufacturer's recommendations.

13. Each panel shall be provided with a separate copper power grounding bus (safety) in accordance with the requirements of the National Electrical Code.

14. Each panel shall have control, signal, and communication line surge suppression in accordance with Section 13300.

15. All microprocessor-based electronic devices in the panel that are powered by 120VAC shall be powered by the UPS (refer to appropriate Section in Division 13).

16. Each panel shall be provided with a circuit breaker to interrupt incoming power.

17. Additional electrical components including transformers, motor starters, switches, circuit breakers, etc. shall be in compliance with the requirements of Division 16.

B. Relays not provided under Division 16 and required for properly completing the control function specified in Division 13, Division 16, or shown on the Drawings shall be provided under this Section.

C. The orientation of all devices including PLC and I/O when installed shall be per the manufacturer's recommendations. No vertical orientation of PLC racks shall be allowed unless specifically indicated by the manufacturer as an acceptable mounting alternative and also approved by the engineer.

2.8 ELECTRICAL COMPONENTS

A. The main circuit breaker shall be a thermal-magnetic molded case breaker, by Square D Company, or equal. Provide a flange mounted main power disconnect operating handle with mechanical interlock having a bypass that will allow the panel door to open only when the switch is in the OFF position.

Bid Set April 2017



B. A mechanical disconnect mechanism, with bypass, shall be installed on each motor circuit protector, capable of being locked in the "OFF" position to provide a means of disconnecting power to the motor.

C. Auxiliary contacts shall be provided for remote run indication and indication of each status and alarm condition. Additional controls shall be provided as specified herein and as required by the detailed mechanical equipment requirements, the P&IDs (Division 13), the Control Wiring Diagrams (Division 16) and as shown on the Drawings.

D. All operating control devices and instruments shall be securely mounted on the exterior door. All controls shall be clearly labeled to indicate function and shall be in accordance with the electrical area classification indicated on the Electrical Contract Drawings.

E. A six digit, non-resettable quartz time base elapsed time meter shall be connected to each motor starter. Meter shall be Hobbs 98000 Series, Redington Model 722, Cramer Model ETI-635 G, or equal.

F. The control panel shall be provided with a lightning and surge protection unit on the line side of the main circuit breaker. Unit shall be 600 Volt, 3 Phase, General Electric "Tranquell" Series, or equal.

G. Where required by Specifications, an alternator shall be provided to sequence motors. Alternator shall be Catalog No. 008-120-13SP or 009-120-23AP by Stacon; Square D, Class 9039, Type HG-21 or equal.

H. Panel mounted timers shall be flush mounted, plug-in type, Eagle Signal Bulletin 125 cycle-flex, Idec SR6P-MO8G or equal, with ranges as shown on the Drawings, or as required by the detailed mechanical equipment specifications.

I. Specific control devices, control descriptions and other data are specified under the detailed specification for the mechanical equipment with which the control panel is supplied.

2.9 OPERATOR INTERFACE TERMINAL (OIT)

A. Provide as specified under Section 13311.

2.10 INDICATOR, BAR GRAPH

A. Type: Electronic bar graph; nominal 4-inch vertical scale and digital indicator.

B. Operation: To accept 4-20 mA DC input signal and provide an indication of measured variable on a vertical scale; microprocessor based with solid state circuitry; 101 segment bar graph and digital readout.

C. Functional:

1. Input: 4-20 mA DC into 250 OHMS maximum.

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2. Indication: 4-inch scale graduated in engineering units.

D. Physical:

1. Case size: nominal 1 inch x 6 inch

2. Case type: dust and moisture resistant (NEMA 4X)

3. Mounting: flush panel suitable for high density mounting arrangements.

E. Performance: Accuracy (bar graph) plus or minus 2.0 percent; (digital indicator) plus or minus 0.1 percent of span.

F. Manufacturer(s):

1. Ametek Dixson.

2. Foxboro.

3. Moore Products.

4. Equal.

2.11 PILOT TYPE INDICATING LIGHTS

A. Type: Energy efficient Solid State LED Lamps.

B. Functional:

1. Units shall be provided with low voltage LED lamps suitable for the voltage supplied.

2. Lights supplied with 120V AC power shall have integral reduced voltage transformers.

3. Lamps shall be replaceable from the front of the unit.

C. Physical:

1. Lens color:

a. Running, on, open – Red.

b. Stopped, off, closed – Green.

c. Alarm – Amber.

d. White - Power on

e. Blue - All other status indications not covered by the above

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f. Lens caps shall be approximately .46-inch diameter. Provide legend faceplates engraved to indicate the required function of each device; NEMA rating - 4X.

D. Manufacturer(s):

1. Cutler-Hammer.

2. Allen Bradley.

3. General Electric.

4. Square D.

5. Crouse Hinds (NEMA 7).

6. Equal.

2.12 SELECTOR SWITCHES AND PUSHBUTTONS

A. Type:

1. Control devices shall be heavy-duty oil tight type with stackable contact blocks.

B. Functional:

1. Provide contact arrangement and switching action as required for the control system specified.

C. Physical:

1. For 120 VAC service provide contacts rated 10 amps at 120 VAC, for 24 VDC service provide silver sliding contacts rated 5 amps at 125 VDC, for electronic (millivolt/ milliamp) switching provide contacts rated lamp at 28 VDC.

2. Pushbuttons shall have flush type operators.

3. Selector switches shall have knob or wing lever operators; NEMA rating - 4X; Provide legend plates denoting switch/pushbutton position/ function.

D. Manufacturer(s):

1. Cutler-Hammer.

2. Allen Bradley.

3. General Electric.

4. Square D.

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5. Crouse Hinds (NEMA 7).

6. Equal.

2.13 POTENTIOMETER

A. Type:

1. Device shall be heavy-duty 30 mm oil tight type.

B. Functional:

1. 270 degree dial

2. Rated for 1,000 ohms.

C. Physical:

1. Mounting: Suitable for panel mounting

2. NEMA 4X rating; escutcheon plates scaled in engineering units.

D. Manufacturer(s):

1. Allen Bradley Co.

2. Cutler-Hammer.

3. Square D.

4. Equal.

2.14 GENERAL PURPOSE RELAYS AND TIME DELAYS

A. Type:

1. General purpose plug-in type.

B. Functional:

1. Contact arrangement/function shall be as required to meet the specified control function; Mechanical life expectancy shall be in excess of 10 million.

2. Duty cycle shall be rated for continuous operation; Units shall be provided with integral indicating light to indicate if relay is energized.

3. Solid state time delays shall be provided with polarity protection (DC units) and transient protection.

4. Time delay units shall be adjustable and available in ranges from .1 second to 4.5 hours.

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C. Physical:

1. For 120 VAC service provide contacts rated 10 amps at 120 VAC, for 24 VDC service provide contacts rated 5 amps at 28 VDC, for electronic (milliamp/millivolt) switching applicator provide gold plated contacts rated for electronic service; relays shall be provided with dust and moisture resistant covers.

D. Options/Accessories Required:

1. Provide mounting sockets with pressure type terminal blocks rated 300 volt and 10 amps.

2. Provide mounting rails/holders as required.

E. Manufacturer(s):

1. Allen Bradley.

2. Potter & Brumfield.

3. Equal.

2.15 SIGNAL ISOLATORS/BOOSTERS/CONVERTERS

A. Type:

1. Solid state, ASIC technology; electronic type.

B. Functional:

1. Accuracy: 0.15 percent.

2. Inputs: Current, voltage, frequency, temperature, or resistance as required.

3. Outputs: Current or voltage as required.

4. Isolation: There shall be complete isolation between input circuitry, output circuitry, and the power supply.

5. Adjustments: Zero and span adjustment shall be provided.

6. Protection: Provide RFI protection.

C. Physical:

1. Mounting: DIN Rail.

D. Manufacturer(s):

1. Action Instruments Slim Pak.

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2. Acromag.

3. Equal.

2.16 INTRINSIC SAFETY BARRIERS

A. Type:

1. Barriers shall be of the solid state electronic type in which the energy level of the sensing or actuation circuit is low enough to allow safe usage in hazardous areas.

2. Provide a barrier for instrumentation and equipment transmitting analog or digital signals that originate in a hazardous area as indicated in the design documents.

B. Options Required:

1. Barriers shall match power supply provided.

2. Barriers shall be located in non-hazardous areas.

C. Manufacturer(s):

1. Siemens Water Technologies – IS1 (4-20mA) and IS6 (dry contacts)

2. Gems – 54800 (4-20mA) and 65800 (dry contacts)

3. R. Stahl - Intrinspak

4. Equal.

2.17 INTRINSIC SAFETY BARRIERS (FOR 2-WIRE TRANSMITTER SYSTEMS)

A. Intrinsic safety barriers shall be passive devices requiring no external voltage supply and supplied with series resistors, series fuse and shunt zener diodes to limit the transfer of energy to levels required by intrinsically safe protection between safe and hazardous locations.

B. Unit shall be Factory Mutual approved and certified for use in accordance with National Fire Protection Association (NFPA 493).

C. Manufacturer(s):

1. P&F.

2. Gems.

3. Unitech.

4. Equal.

Bid Set April 2017



2.18 24 VDC POWER SUPPLIES

A. Provide a 24 VDC power supply in the control panel to power field instruments, panel devices, etc., as required. Equip the power supply with a power on/off circuit breaker.

B. The 24 VDC power supply shall meet the following requirements:

1. Input power: 115 VAC, plus or minus 10 percent, 60 Hz.

2. Output voltage: 24 VDC.

3. Output voltage adjustment: 5 percent.

4. Line regulation: 0.05 percent for 10 volt line change.

5. Load regulation: 0.15 percent no load to full load.

6. Ripple: 3 mV RMS.

7. Operating temperature: 32 to 140 degrees Fahrenheit.

C. Size the 24 VDC power supply to accommodate the design load plus a minimum 25 percent spare capacity.

D. If power supply on/off status signal is shown, provide a relay contact (internal to the power supply or external if the power supply is not so equipped) to indicate on/off status of the power supply.

E. Provide output overvoltage and overcurrent protective devices with the power supply to protect instruments from damage due to power supply failure and to protect the power supply from damage due to external failure.

F. Mount the 24 VDC power supply such that dissipated heat does not adversely affect

other panel components.

G. Manufacturer(s):

1. Acopian.

2. Lambda.

3. Equal.

2.19 DIGITAL PANEL METER

A. Type:

1. Electronic, 3.5 digit, 0.56-inch-high efficiency LED display.

B. Operation:

Bid Set April 2017



1. To accept 4-20 mA DC input signal and provide indication in Engineering Units of measured variable.

C. Functional:

1. Power supply: 115 VAC, plus or minus 10 percent, 50/60 Hz, 10 VA.

2. Input: 4-20 mA DC into 100 ohms.

3. Indication: 0.56 inch LED display.

D. Physical:

1. Case size nominal 2.5-inch-high by 5 inch wide by 6 inch deep.

2. Case type: watertight and dust-tight (NEMA 4X).

3. Mounting: flush panel suitable for high density mounting arrangements.

E. Performance: Linear input accuracy plus or minus 0.05 percent of calibrated span, plus or minus 1 count.

F. Manufacturer(s):

1. Precision Digital.

2. Red Lion.

3. Equal.

2.20 SUBMERSIBLE PUMP MOTOR PROTECTION MONITOR

A. Pump/motor protection system shall be provided to monitor machine temperature, and moisture as specified under Section 11306- Submersible Solids Handling Pumps. The system shall provide warning and shutdown protection and shall be UL listed. All of the pump/motor unit protective and monitoring sensors shall be connected to an electronic module which will provide a signal from the pump/motor sensors to the devices located in the electrical/instrumentation panel. Modules shall be mini-CAS as manufactured by Xylem with associated adaptors, appurtenances and relays.

B. Panel mounted devices shall be located within the electrical/instrumentation panel enclosure provided as part of project for WWF PS by the Contractor. Contractor shall fully coordinate the pump protection device requirements of the Manufacturer with the electrical/instrumentation panel furnished for the project.

C. Manufacturer shall provide all transformers required to step 460V to required voltage(s) for pump/motor protection system components.

D. Detailed operational data shall be accessible using a standard web browser on a computer with no special software required (future function).

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E. The pump/motor protection system shall monitor each pump/motor’s temperature, and moisture (leakage). The system shall be provided with Ethernet, Modbus and modem communications ports, and shall be capable of communicating with the PLC to provide alarming.

F. The pump/motor protection module, relays and associated devices shall be mounted

within the new electrical/instrumentation panel for WWF PS. The pump/motor protection components shall include leakage and temperature alarm indication, power applied indication, temperature alarm reset mode selection switch, temperature alarm reset push-button and sensor input transient and short circuit protection.

2.21 SPARE PARTS

A. General requirements for spare parts are specified in section 13300.

B. The following control panel spare parts shall be furnished:

1. Timers and sockets - Two of each type installed.

2. Relays and sockets - Two of each type installed.

3. Fuses and circuit breakers - 10 percent (minimum of 10 fuses and 2 circuit breakers) of each type and size installed.

4. Light bulbs - 10 percent (minimum of 10) of each type installed. For LED type lights, 5 percent (minimum of 3) of each color installed.

5. Panel Mounted power supplies - one of each type installed.

6. Selector switches/pushbuttons - Two of each type installed including contact blocks.

7. Provide touch-up paint, of each type and color used for all cabinets, panels, and consoles supplied.

PART 3 EXECUTION

3.1 INSTALLATION

A. The panels shall be installed at locations as shown on the Contract Drawings.

B. Refer to Section 13300.

3.2 TESTS


END OF SECTION

Bid Set April 2017

IC - Control Panel UPS (Single-Phase) 13335 - 1


SECTION 13335

INSTRUMENTATION AND CONTROLS - CONTROL PANEL UNINTERRUPTIBLE POWER SUPPLY

(SINGLE-PHASE)

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Labor, equipment, supervision and materials for the installation, testing, startup, and training for the uninterruptible power supply (UPS) as shown on the Drawings and as specified herein.

1.2 RELATED WORK

A. Section 13300 – Instrumentation and Controls – General Provisions.

B. Section 13330 – Instrumentation and Controls -Control Panel and Panel Mounted equipment.

C. Section 16020 – Electrical.

1.3 SUBMITTALS

A. Submittals shall be in accordance with Sections 01300 and 13300. Submittals shall include shop drawings and product data, for the following:

1. Product brochure.

2. Bill of materials listing all components provided.

3. Deviation list indicating all proposed exceptions.

4. Power single line and control schematics drawings. All external connection details and their terminal block locations shall be fully detailed. All internal wiring shall include terminal numbers and color coding.

5. UPS performance specifications:

a. kVA rating.

b. Input and output voltage and phase.

c. Run time at full and half load.

d. Voltage (output regulation, input tolerance, unbalance, transfer/retransfer voltage, etc.).

e. Heat rejection.

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6. Operating Instruction manuals and recommended replacement parts.

7. Name, address, and telephone number of the nearest service facility.

8. Training agenda and information per Section 01758.

9. Battery specifications and warranty.

10. UPS Loading and battery sizing calculations to support runtimes as specified herein.


A. ANSI C62.41/IEEE 587 - Standards for Surge Withstandability.

B. FCC (Federal Communications Commission) Rules and Regulations, Part 15, Subpart B, Class A certified compliance.

C. UL (Underwriters Laboratories) 1778 Listed (Rev. Jan 5, 2000), UL497A D.

CSA 22.2, No. 107.1 M95 AND 107.2.

E. IEC 62040-2 Emission and Immunity.

F. IEC 62040-3 (Uninterruptible Power Systems, Part 3).

G. EN 60529 Equipment Protection.

H. National Electric Code (NFPA-70).

I. ISO 9001.


A. Provide delivery, storage and handling in accordance with Section 01600 and per the following:

1. Store the equipment indoors in a clean, dry, heated storage facility until ready for installation. Do not install the equipment in its final location until the facilities are permanently weather tight. Furnish, install and wire temporary electric space heaters in the equipment until the permanent heating equipment is operational. Protect the equipment at all times from exposure to moisture and chemicals.


A. UPS systems shall utilize a field proven design. The UPS manufacturer shall demonstrate at least ten years of continuous field operating experience with equipment of similar size and design.

B. A factory authorized service and parts organization shall be located within 100 miles of the project location. Submit the name and address of the factory authorized service

Bid Set April 2017



and parts organization. The manufacturer shall have a complete selection of service options that may include onsite service by factory-employed service engineers and factory depot quick-return service plan options.

C. Equipment shall be UL or ETL labeled.

D. The UPS manufacturer shall have ISO 9001 certification.

E. The UPS system shall meet or exceed the theoretical Mean-Time-Between-Failures (MTBF) for a Single module UPS operation (represents UPS module operation only) of 140,000 MTBF hours.

1.7 WARRANTY


B. UPS: In addition to the basic warranty, the UPS manufacturer shall provide a standard warranty for the UPS for a period of one year from the date of purchase. The Contractor shall provide an additional one-year extended warranty to cover delays associated with equipment startup or date of receipt by end user, whichever occurs first.

C. Battery: In addition to the basic warranty, the UPS manufacturer shall provide a standard warranty for the batteries for a period of one year from the date of purchase. The Contractor shall provide an additional one-year extended warranty to cover delays associated with equipment startup or date of receipt by end user, whichever occurs first.

PART 2 PRODUCTS

2.1 SINGLE PHASE UPS - INTERNAL TO CONTROL PANELS

A. SYSTEM DESCRIPTION

1. Provide an industrially rated continuous-duty, on-line, solid state, line interactive, single-phase uninterruptible power system.

2. The UPS shall provide power conditioning and power backup for PLC, communications hardware, and other critical electronic loads as indicated on the Drawings.

3. The UPS system shall consist of the following major components:

a. Rectifier and battery charger.

b. Inverter.

c. Batteries.

d. Other features as described in this specification and as indicated on the Drawings.

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4. The UPS shall be

a. Allen Bradley 1609-U UPS

b. Sola Hevi Duty SDU UPS

c. Or equal

B. GENERAL REQUIREMENTS

1. Battery protection shall be provided an internal circuit breaker disconnect.

2. Current limiting circuitry shall protect the inverter output under any load condition.

3. The AC output neutral shall be electrically isolated from the UPS chassis. The UPS chassis shall have an equipment ground terminal. Provisions for installation of a bonding connector shall be provided.

4. The UPS shall be suitable for installation in a UL508A listed panel.

5. The UPS shall be DIN rail mountable.

6. UL recognized components for industrial applications in accordance with UL508 without derating.

C. PERFORMANCE REQUIREMENTS

1. Ratings

a. Output power: 1000VA

b. Battery runtime: 15 minutes at full-load, 34 minutes at half-load

2. Environment:

a. Ambient temperature: 0 to 40 degrees C.

b. Elevation: Up to 500-ft above mean sea level

c. Relative humidity: 1 to 95 percent non-condensing

3. System Input – Primary source:

a. Single input: Nominal Input Voltage: 120 VAC

b. Frequency: 45 to 65 Hz.

c. Input Power Factor: 0.95 lag minimum, 50 to 100 percent load.

d. Input Surge Withstandability: Per IEEE 587/ANSI C62.41. Category A and B, (6 kV).

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4. System Output:

a. Nominal Output Voltage:120 VAC

b. Frequency: 60 Hertz plus or minus 3 Hertz.

c. 100 percent load with 3:1 Crest Ratio

d. Frequency Slew Rate: 1 Hz/second. (Adjustable at startup)

5. AC to AC Efficiency: (100 percent load @ rated PF): 88 percent online, 86 percent on battery.

6. Acoustical Noise: Noise generated by the UPS under normal operation shall not exceed 65 dBA (60 dBA typical) at one meter from any surface, measured at 25 degrees C (77 degrees F) and full load.

7. EMI Suppression: The UPS shall meet FCC Rules and Regulation 47, Part 15, Subpart J, for Class A devices.

D. MODES OF OPERATION

1. The UPS shall operate as a line interactive on-line, fully automatic system in the following modes:

a. Normal: The critical load shall be continuously supplied with filtered and

regulated AC power by the inverter. The rectifier/battery chargers shall derive power from the preferred AC source and supply DC power to the inverter while simultaneously floats charging the batteries.

b. Emergency: Upon failure of the preferred ac power source, the critical load shall

continue to be supplied by the inverter. Inverter power shall be supplied without switching from the storage battery. There shall be no interruption to the critical load upon failure or restoration of the preferred ac sources. If the AC source cannot be restored before the battery discharges to its low voltage dropout value, the UPS shall automatically shut itself down in an orderly manner.

c. Recharge: Upon restoration of the AC source, the rectifier/battery charger shall

power the inverter and simultaneously recharges the batteries. This shall be an automatic function causing no interruption to the critical load.

E. RECTIFIER/CHARGER

1. The term rectifier/charger shall denote the solid-state equipment and controls necessary to convert incoming AC power to regulated DC power for input to the inverter and for battery charging. The rectifier/charger shall be a solid-state SCR/IGBT power transistor type with constant voltage/current limiting control circuitry.

Bid Set April 2017



F. INVERTER

1. The inverter shall include all solid-state equipment and controls to convert DC power from the rectifier/charger or battery to a regulated AC power for powering the critical load. The inverter shall use Insulated Gate Bipolar Transistors (IGBTs) in a phase-controlled, pulse width modulated (PWM) design capable of providing the specified AC output.

2. The inverter shall be capable of supplying current and voltage for overloads exceeding 100 percent. The inverter is to provide 150 percent of full load for 30 seconds and 125 percent of full load for 2 minutes. A status indicator and audible alarm shall indicate overload operation.

3. The output voltage shall be maintained to within plus or minus 5 percent.

4. The output voltage total harmonic distortion (THD) shall not be greater than 5 percent at full load.

G. BATTERIES

1. The batteries shall be High Temperature sealed, maintenance-free, high-rate discharge, lead-acid cells suitable for use indoors with no off gassing, or water addition requirements. Batteries shall not require special ventilation. The battery shall consist of one or more battery banks with the number of cells required to meet the requirements of the rest of these specifications.

2. Battery Design Life: two-four years.

H. CONTROLS AND MONITORING

1. Microprocessor-controlled circuitry: Fully automatic operation of the UPS shall be provided through the use of a microprocessor-based controller. All operating and protection parameters shall be firmware-controlled. The logic shall include system test capability to facilitate maintenance and troubleshooting. Startup, battery charging, and transfers shall be automatic functions.

2. Front Indicators: As a minimum, the following indicators shall be provided on the UPS control panel:

a. On-line (UPS is using utility power to power the load)

b. In bypass mode

c. On battery

d. Overload

e. Replace battery / battery disconnected

f. Fault

Bid Set April 2017



g. Bar graph for utility voltage

h. Bar graph for battery

3. Front Panel Controls: As a minimum, the following controls shall be provided on the UPS control panel

a. Power On/Off

b. Self-test

c. Alarm silence

d. Cold start

e. Load off

4. Remote alarm and status indication: Isolated SPDT dry contacts shall be provided to indicate UPS status for remote monitoring. Contacts shall be rated for 250VAC @ 5A or 30VDC @ 5A Individual contacts shall be provided for separate annunciation of the following alarm and status conditions:

PART 3 EXECUTION

3.1 INSTALLATION

A. Install and connect the equipment in accordance with the manufacturer's instructions.

B. Remove temporary lifting angles, lugs and shipping braces.

C. Touch up damaged paint finishes.

3.2 FACTORY TESTING

A. Prior to shipment, the complete UPS system shall undergo the manufacturer's standard factory test.

3.3 FIELD TESTING

A. Perform the following minimum test and checks:

1. Verify that all connections are completed in accordance with shop drawings.

2. Verify supply voltage and phase sequence are correct.

3. Check mechanical interlocks for proper operation.

4. Test ground connections for continuity and resistance.

5. Check control circuit interlocking and continuity.

Bid Set April 2017



B. Submit the test plan for review and approval.

C. For UPSs rated 3-6kVA, the manufacturer's field service technician shall perform startup and adjustment of the UPS in accordance with the manufacturer's written instructions. Submit a copy of the field report containing verification of all startup tests and adjustments performed.

D. The Contractor shall include testing of battery runtime under full load with loss of AC power.

E. Perform all additional tests required by Section 16950 Electrical Acceptance Testing.

F. In the event of an equipment fault, notify the Engineer immediately. After the cause of the fault has been identified and corrected, a joint inspection of the equipment shall be conducted by the Contractor, the Engineer and the equipment manufacturer's factory service technician. Repair or replace the equipment as directed by the Engineer.

3.4 ADJUSTMENT

A. Make all UPS adjustments necessary for manual and automatic operation of the entire system.

3.5 CLEANING

A. Remove all rubbish and debris from inside and around the equipment. Remove dirt, dust, or concrete spatter from the interior and exterior of the equipment using brushes, vacuum cleaner, or clean, lint free rags. Do not use compressed air.

3.6 TRAINING

A. Provide training of staff in accordance with Section 01758 and Section 13303.

END OF SECTION

Bid Set April 2017

IC - Instruments 13340 - 1


SECTION 13340 INSTRUMENTATION

AND CONTROLS – INSTRUMENTS

PART 1 GENERAL

1.1 SCOPE OF WORK

A. This section covers the furnishing, installation, and services for instruments.

B. Refer to Section 13300.

1.2 RELATED WORK


1.3 SUBMITTALS

A. Submit complete documentation of all field instruments using ISA-TR20.00.01-2001 (updated in 2004-2006) data sheet formats. Submit a complete Bill of Materials (BOM) or Index that lists all instrumentation equipment. The list shall be sorted by Loop Number.

B. Submit separate data sheets for each instrument including:

1. Plant Equipment Number and ISA tag number per the Drawings.

2. Product (item) name used herein and on the Drawings.

3. Manufacturer's complete model number.

4. Location of the device.

5. Input - output characteristics.

6. Range, size, and graduations in engineering units.

7. Physical size with dimensions, enclosure NEMA classification and mounting details in sufficient detail to determine compliance with requirements.

8. Materials of construction for enclosure and wetted parts.

9. Instrument or control device sizing calculations where applicable.

10. Certified calibration data for all flow metering devices.

11. Two-wire or four-wire device type as applicable.

C. Submit catalog cuts for all instruments. Submit descriptive literature for each hardware component, which fully describes the units being provided.

Bid Set April 2017



D. Submit index and data sheets in electronic format as well as hard copies on 8-1/2- by 11-inch formats. Electronic format shall be in Microsoft Excel or Word. Submit electronic copy on CD-ROM or DVD disk.

1.4 MAINTENANCE


1.5 INSTRUMENT TAGS

A. A permanent stainless steel or other non-corrosive material tag firmly attached and permanently and indelibly marked with the instrument tag number, as indicated in the Drawings, shall be provided on each piece of equipment supplied under this Section and related sections. Equipment shall be tagged before shipping to the site.

B. Provide 1/8-inch by 3/8-inch, Type 316 stainless steel button head machine screws.

C. All supplied instrument transmitters and instrument transmitter elements shall have stainless-steel identification tag attached to each transmitter and element prior

to shipment. Tag shall be attached via stainless steel chain or stainless steel wire (24-gauge min) to a non-removable part of the device. The tag size shall be a minimum of 1.5 square inches. Tag shall include the ISA alphanumeric instrument number as indicated in the P&ID, loop, and detail drawings. The alphanumeric instrument number shall be stamped into the tag and shall have a minimum of 3/16-in high alphanumeric characters.

1.6 APPROVALS/CERTIFICATIONS

A. Instruments for hazardous locations shall have Factory Mutual (FM), Canadian Standards Association (CSA), and CENELEC approvals and certifications as specified herein and as indicated on the Drawings or in the Instrument Device Schedule. The instrument specifications in Part 2 state the Class, Division, and gas groups for FM/CSA approval, followed in parenthesis by the CENELEC certification; however, instruments provided are only required to have the approval/certification stated above. The instrument shall have a stainless-steel tag identifying the relevant approval or certification.

1.7 MANUFACTURERS’ START-UP AND TRAINING SERVICES

A. If indicated in the individual instrumentation paragraphs, the instrument manufacturer or manufacturer's certified service representative shall provide start-up and training services. This work shall not be done by the PCSS or AESS contractor.

B. The start-up services shall be to calibrate, oversee the installations of the sensor, and start-up the sensor/transmitter in order to provide reliable measurement at the instrument and to a remote system. The vendor shall work with the PCSS and AESS to verify the transmitter sends correct information to the remote system (i.e., that the scaling and units are the same at the instrument and on the remote operator interface).

C. While the instrument manufacturer or manufacturer’s certified service representative is starting up the instrumentation, training shall be provided to the Owner's

Bid Set April 2017



instrumentation technicians. The training shall be in how to calibrate, install, troubleshoot, read the diagnostics, and maintain the sensor and transmitter.

PART 2 PRODUCTS

2.1 TRANSIT TIME ULTRASONIC FLOWMETER

A. Flow Element

1. Type:

a. Externally mounted non-intrusive transit time type.

b. Strap on sensor design.

2. Function/Performance:

a. Measuring Range: As required by range indicated in the Instrument Device Schedule up to 50 ft/s (15 m/s).

b. Operating Temperature: -29 to 149 degrees F.

3. Physical:

a. Encapsulated submersible transducer.

4. Power Requirements: a. Transducer shall receive its power from the remote transmitter.

5. Accessories/Documentation Required:

a. Provide a certificate of conformance/calibration subsequent to installation for each flowmeter.

b. Manufacturer's cable for connection of transducer to transmitter. Length as

required by installation indicated on drawings.

c. 304 stainless steel strap on hardware for installation on piping as indicated on the Drawings.

B. Transmitter

1. Type:

a. Microprocessor based, compatible with transducers provided.


a. Accuracy (including flow element): Plus or minus 1 percent.

b. Sensitivity (including flow element): 0.005 ft/s (0.0015 m/s).

Bid Set April 2017



c. Operating Temperature: 32 to 140 degrees F.

d. Output: One isolated 4-20 mA output adjustable over the low range and scaled in engineering units.

e. Diagnostics: On screen display of self-diagnostics and calibrated parameters.

f. Display: Digital indicator displaying flow in engineering units indicated on the

Drawings or in the Instrument Device Schedule.

g. Totalizer: A fully configurable totalizer integral to the transmitter. Totalized flow shall be displayed.

3. Physical:

a. Transmitter shall be suitable for surface mounting.

b. Enclosure shall be NEMA 4X (IP65).

4. Power Requirements:

a. Transmitter shall be 120 VAC powered instrument.

C. Manufacturer:

1. Accusonic Model 7658 Transducer, and Model 8510 Transit-Time Flow Transmitter.

2. Badger Series 4500 Compu-Sonic.

3. Polysonics DCT 6088.

4. Siemens Sitrans Model FUS

5. Equal.

2.2 SUBMERSIBLE LEVEL TRANSMITTER

A. Type

1. Submersible, hydrostatic pressure type level transmitter.

B. Function/Performance

1. Range: Range selected shall be the manufacturer's standard range closest to the span to be measured.

2. Temperature Compensation: Temperature compensated over a range of zero to 50 degrees C.

3. Accuracy: Plus or minus 0.25 percent of range.

Bid Set April 2017



4. Over Pressure: Transducer shall be protected for over pressure of 1.5 times the span.

5. Output: 4-20 mA proportional to the calibrated span.

C. Physical

1. The transmitter assembly shall have a Type 316 stainless steel or titanium body with a bottom diaphragm.

2. Sensors shall be suspended by cable. Cable shall include a vent tube for the transducer.

3. Sensor shall be suspended with a tension-relieving mounting clamp from a four- inch (100 mm) flange. Clamp and flange shall be Type 316 stainless steel.

4. Sensor shall be submersible (IP68), and shall be CSA approved or CENELEC (EEx ia IIC T4) certified intrinsically safe when intrinsically safe barriers are provided for the instrument loop.

5. 24 VDC loop powered.

D. Accessories Required

1. Sufficient manufacturer's cable for installation between the sensor and the transmitter as indicated on the Drawings. Cable shall be reinforced to support the weight of the transducer and cable.

2. Cable clamp for suspending instrument provided by instrument supplier.

3. All fittings required for pressure calibration of the instrument.

E. Manufacturer(s)

1. Measurement Specialties KPSI model 750

2. SOR 510LT.

3. GE PTX1290.

4. Or Equal.

2.3 FLOAT SWITCHES

A. Type

1. Mercury free ball float switch.

B. Function/Performance

1. Differential: Less than 8 inch.

Bid Set April 2017



2. Switch Rating: 1 amps at 120 VAC or 100 VA @ 120 VAC

3. Provide NO or NC type contact for fail-safe operation per Section 13300, Paragraph 2.01.F or as shown on the Drawings.

C. Physical

1. Float: Type 316 stainless steel, Teflon or non-stick coating, minimum 5 in diameter.

2. Totally encapsulated switch.

3. Cable shall be heavy-duty, PVC or equivalent jacketed integral to float.

D. Options/Accessories Required

1. Provide stainless steel hardware.

2. Providing mounting as shown on Drawings.

3. Lead wire shall be a waterproof cable of sufficient length so that no splice or junction box is required in the vault.

4. Provide cast-aluminum weatherproof junction box outside the sump pit with terminals for all floats and tapped as required for conduit connections.

E. Manufacturer(s)

1. Siemens Water Technologies Model 9G-EF.

2. Contegra FS 90

3. Or equal.

2.4 OIL IN WATER SENSOR

A. Sensor:

1. Type:

a. UV fluorescence method for polycyclic aromatic hydrocarbons (PAH).

b. Capable of continuous submersed operation.


a. UV-fluorescence technology with excitation at 254nm and emission detection at 360 nm wavelength.

b. Response Time: T90 in less than 15 seconds.

Bid Set April 2017



c. Range: 0.1-15 ppm (mg/L oil).

3. Physical:

a. Corrosion resistant metal housing with a stain resistant measuring window.

4. Accessories Required:

a. Manufacturer's cable for connection of sensor to transmitter. Length as required by installation indicated on the Drawings.

b. One year's supply of consumables for calibration.

5. Manufacturer(s):

a. Hach FP 360 sc UV Fluorescence Sensor (for oil in water detection and measurement).

b. Or equal.

B. Transmitter:

1. Include compatible transmitter by same manufacturer as specified below.

C. Manufacturer Start-up and Training services:

1. Provide manufacturer's start-up and training services.

2.5 SINGLE-PARAMETER UNIVERSAL TRANSMITTER

A. Type:

1. Microprocessor-based, intelligent transmitter compatible with a minimum of sensor (digital or analog) inputs.

2. Transmitter manufacturer shall be same as instrument sensor where possible.

B. Function/Performance:

1. Accuracy: ± 0.1 percent of span.

2. Repeatability: ± 0.05 percent of span.

3. Response Time: 60 seconds to 90 percent of value on a step change.

4. Temperature Compensation: Compensation over entire temperature range of the instrument.

5. Environmental Conditions: -10 to 55 degrees C and 5 to 95 percent relative humidity.

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6. Outputs:

a. Minimum: (2) 4-20mA outputs.

b. Minimum: (3) 120VAC, 5A, configurable relays.

7. Diagnostics: On screen instructions and display of self-diagnostics.

C. Physical:

1. Transmitter shall be suitable for surface or pipe stand mounting.

2. Enclosure shall be NEMA 4X (IP65).

3. Power Requirements: 120VAC powered.

D. Accessories:

1. Provide sensor connection cable and plug between the transmitter and the analyzer sensor for rapid attachment and exchange of sensor.

2. Provide connection box for analyzers.

E. Manufacturer Start-up and Training services:

1. Provide manufacturer’s start-up and training services.

F. Manufacturers:

1. Hach – SC200.

2. Or equal.

2.6 HYDROCARBON GAS/LEL DETECTOR

A. Sensor:

1. Type:

a. Intrinsically safe.

b. Continuous infrared sensor.


a. Response Time: T90 in less than 30 seconds.

b. Temperature Range: -50 to 90 degrees C.

c. Sensor Life: 3 years typical.

Bid Set April 2017



3. Physical:

a. Infrared sensor technology.

b. Suitable for remote wall or ceiling mounting, or directly fitted to transmitter as indicated on the Drawings.

4. Accessories Required:

a. Sufficient cable up to 50 ft (15 m) of the type recommended by the manufacturer shall be provided for installation between sensor and transmitter as required by the installation indicated on the Drawings.

b. Remote sensor enclosures shall be explosion proof, approved for Class 1,

Division 1, Groups C and D (EEx d IIC T4) areas.

c. Detectors shall be fitted with splash guards supplied by the manufacturer, to protect the sensor from accidental wetting.

B. Remote Indicating Transmitter/Controller:

1. Type:

a. Electronic, microprocessor based single channel transmitter compatible with sensor provided.


a. Accuracy: ± 3 percent up to 50 percent LEL, ±5 percent for greater than 50 percent LEL.

b. Range: 0 to 100 percent LEL.

c. Environmental Conditions: -20 to 60 degrees C; 10 to 95 percent relative

humidity.

d. Output: One 4-20 mA output proportional to calibrated range. Two programmable relay contacts for warning, alarm, and/or fault.

e. Display: Digital display indicating the gas level, alarm or fault messages, and

diagnostic information.

3. Physical:

a. Explosion proof enclosure approved for Class 1, Division 1, Groups B, C, and D (EEx d IIC T4).

b. Suitable for surface mounting.

Bid Set April 2017



4. Accessories Required: a. Handheld programming unit if required for setup and calibration.

C. Manufacturer(s):

a. MSA Ultima XIR Series.

b. Or equal.

D. Manufacturer Start-up and Training services:

1. Provide manufacturer's start-up and training services.

2.7 SPARE PARTS AND ACCESSORIES

A. General requirements for spare parts are specified in Section 13300.

B. The following field Instrument related Spare Parts shall be furnished:

1. One flow indicating transmitter for each type of flow element provided.

2. One pressure transmitter for each type provided.

3. One spare float type level switch for each type provided.

C. The following accessories shall be furnished:

1. All mounting hardware required for pipe stand, surface, or other mounting shall be provided.

2. Each instrument shall be provided with a manufacturer installed stainless steel tag identifying the instrument tag number.

PART 3 EXECUTION

3.1 GENERAL

A. See execution requirements in Section 13300.

B. Unless specifically indicated, direct reading or electrical transmitting instrumentation shall not be mounted on process piping. Instrumentation shall be mounted on instrument racks or stands. All instrumentation connections shall be provided with shutoff and drain valves. For differential pressure transmitters, 5-valve manifolds for calibration, testing and blow down service shall also be provided. For chemical or corrosive fluids, diaphragm seals with flushing connections shall be provided.

END OF SECTION

Bid Set April 2017

Piping – General Requirements 15050 - 1


SECTION 15050

PIPING - GENERAL REQUIREMENTS

PART 1 GENERAL

1.1 SCOPE OF WORK

A. This Section specifies the basic administrative and testing requirements for piping. Specific piping materials, systems and related installation and testing requirements are specified in other Sections of Division 15.

1.2 RELATED WORK

A. Piping materials and systems are included in other Sections of Division 15.

B. Valves are included in Section15100.

1.3 SUBMITTALS

A. Submit, in accordance with Section 01300, general submittals for piping and piping systems are listed below. It is not intended that all submittals listed below be provided for all piping materials and systems. Refer to individual System or Piping Sections for specific submittals.

B. Shop Drawings and Product Data

1. Piping layouts in full detail.

2. Location of pipe hangers and supports.

3. Location and type of backup block or device to prevent joint separation.

4. Large scale details of wall penetrations and fabricated fittings.

5. Schedules of all pipe, fittings, special castings, couplings, expansion joints and other appurtenances.

6. Catalog cuts of joints, couplings, harnesses, expansion joints, gaskets, fasteners and other accessories.

7. Brochures and technical data on coatings and linings and proposed method for application and repair.

C. Samples

D. Design Data

E. Test Reports

Bid Set April 2017



1. A minimum of four copies of certified shop tests showing compliance with appropriate standard.

2. A minimum of four copies of all field test reports, signed by Contractor.

F. Certificates

1. Copies of certification for all welders performing work in accordance with ANSI B31.1.

G. Manufacturers Installation (or application) instructions.

H. Statement of Qualifications

I. Manufacturers Field Report

J. Project Record Document

K. Operation and Maintenance Data in accordance with Section 01730.

L. Warranties



1. ASTM A307 - Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength

B. American National Standards Institute (ANSI)

1. ANSI B16.5 - Pipe Flanges and Flanged Fittings

2. ANSI B31.1 - Power Piping

C. American Welding Society (AWS)

1. AWS B2.1 - Specification for Welding Procedure and Performance Qualifications

D. American Water Works Association (AWWA)

1. AWWA Manual M11 - Steel Pipe - A Guide for Design and Installation

E. American Society of Mechanical Engineers (ASME)

F. Underwriters Laboratories (UL)

G. Factory Mutual (FM)


Bid Set April 2017




A. All materials shall be new and unused.

B. Install piping to meet requirements of local codes.

C. Provide manufacturer's certification that materials meet or exceed minimum requirements as specified. Reference to standards such as ASTM and ANSI shall apply to those versions in effect at the time of bid opening.

D. Coordinate dimensions and drilling of flanges with flanges for valves, pumps and other equipment to be installed in piping systems. Bolt holes in flanges to straddle vertical centerline.

E. Reject materials contaminated with gasoline, lubricating oil, liquid or gaseous fuel, aromatic compounds, paint solvent, paint thinner and acid solder.

F. Pipe-joint compound, for pipe carrying flammable or toxic gas, must bear approval of UL or FM.

G. Unless otherwise specified, pressures referred to in all Piping Sections are expressed in pounds per square in gauge above atmospheric pressure, psig and all temperature are expressed in degrees Fahrenheit (F).


A. During loading, transportation and unloading take care to prevent damage to pipes and coating. Carefully load and unload each pipe under control at all times. Place skids or blocks under each pipe in the shop and securely wedge pipe during transportation to ensure no injury to pipe and lining.

PART 2 PRODUCTS

2.1 MATERIALS

A. Specific piping materials and appurtenances are specified in the respective Piping or System Sections.

B. General installation materials shall be as specified below.

1. Unions shall be brass or bronze unions for joining nonferrous pipe; malleable brass or bronze-seated iron or steel unions for joining ferrous pipe; PVC unions for joining PVC pipe; CPVC unions for joining CPVC pipe.

2. Flanged Joints. Bolt and nuts, Grade B, ASTM A307, bolt number and size same as flange standard; studs - same quality as machine bolts; 1/16-in thick rubber gaskets with cloth insertions; rust-resistant coatings.

3. Temporary Plugs shall be standard plugs or caps which are suitable for permanent service.

Bid Set April 2017



4. Flexible Connections shall be as specified in Section 15120. All flexible joints shall be rated for the working pressure of the system in which they are installed.

PART 3 EXECUTION

3.1 GENERAL

A. All dirt, scale, weld splatter, water and other foreign matter shall be removed from the inside and outside of all pipe and sub-assemblies prior to installing.

B. All pipe joints and connections to equipment shall be made in such a manner as to produce a minimum of strain at the joint.

C. Install piping in a neat manner with lines straight and parallel or at right angles to walls or column lines and with riser’s plumb. Run piping so as to avoid passing through ductwork or directly under electric light outlets and/or interference with other lines. All work shall be accomplished using recognized methods and procedures of pipe fabrication and in accordance with the latest revision of applicable ANSI Standards, ASME Codes and Pipe Fabrication Institute Standards.

1. Use full length of pipe except where cut lengths are necessary. Do not spring or deform piping to make up joints.

2. Pipe shall be cut square, not upset, undersize or out of round. Ends shall be carefully reamed and cleaned before being installed.

a. Bending of pipe is not permitted. Use fittings for all changes in direction.

3. Do not use bushings except where specifically approved by the Engineer. Reducers shall be eccentric to provide for drainage from all liquid-bearing lines and facilitate air removal from water lines.

4. Verify the locations and elevations of any existing piping and manholes before proceeding with work on any system. Any discrepancies between the information shown on the Drawings and the actual conditions found in the field shall be reported at once to the Engineer. No claim for extra payment will be considered if the above provision has not been complied with.

5. Where lines of lower service rating tie into services or equipment of higher service rating the isolation valve between the two shall conform to the higher rating.

6. Mitering of pipe to form elbow is not permitted.

7. All piping interiors shall be thoroughly cleaned after installation and kept clean by approved temporary closures on all openings until the system is put in service. Closures should be suitable to withstand the hydrostatic test.

8. End caps on pre-cleaned pipe shall not be removed until immediately before assembly. All open ends shall be capped immediately after completion of installation.

Bid Set April 2017



D. Test Connections

1. Provide 1/2-inch female NPT test connection equipped with 1/2-inch brass plug on all pump suction and discharge lines. Where indicated on the Drawings, test connections should be equipped with bar stock valve and gauge. Provide test connections at all steam traps. The connection shall be located on the discharge side of the trap between the trap and the first valve. It shall consist of a 1/2-inch branch connection terminated with a gate valve.

E. Unions

1. Unions screwed or flanged shall be provided where indicated and in the following locations even if not indicated.

a. In long runs of piping to permit convenient disassembly for alterations or

repairs.

b. In by-passes around equipment.

c. In connections to tanks, pumps and other equipment between the shut-off valve and the equipment.

d. In connections on both sides of traps, controls and automatic control valves.

F. Vents and Drains

1. Provide vents and drains in the following places:

a. Stormwater Lines - Vents at high points and drains at low points. 3.2 UNIONS

A. Use unions to allow dismantling of pipe, valves and equipment.

3.3 WELDING

A. Welding in accordance with ANSI B31 and AWS B3.0.

B. Install welding fittings on all welded lines. Make changes in direction and intersection of lines with welding fittings. Do not miter pipes to form elbows or notching of straight runs to form tees, or any similar construction. Do not employ welder who has not been fully qualified in above specified procedure and so certified by approved welding bureau or similar locally recognized testing authority.

3.4 FLANGED JOINTS

A. Make flanged joints with bolts; bolt studs with nut on each end; or studs with nuts where one flange is tapped. Use number and size of bolts conforming to same ANSI Standard as flanges. Before flanges pieces are assembled, remove rust resistant coating from machined surfaces, clean gaskets and smooth all burrs and other defects. Make up flanged joints tight, care being taken to prevent undue strain upon valves or other pieces of equipment.

Bid Set April 2017



3.5 SLEEVE COUPLINGS

A. Install tierods, pipe clamps or bridles when sleeve type couplings or fittings are used in piping system where indicated, and at changes in direction or other places as necessary, to prevent joints from pulling apart under pressure. Use bridles and tierods at least 3/4-in in diameter, except where tierods replace flange bolts of smaller size, in which case fit with nut on each side of pair of flanges. Joint harnessing shall conform, as a minimum, to the requirements for the bolts and tie bolt lugs as set forth in AWWA Manual M11.

3.6 WALL SLEEVE SEALS

A. Use expandable rubber segmented sealing device with corrosion-resistant fasteners to make watertight the annular space between pipe and sleeve where shown on the Drawings. Determined the required inside diameter of each individual wall opening or sleeve to fit the pipe and seal it to assure a watertight joint as recommended by the manufacturer, before ordering, fabricating or installing. Install pipe concentrically through wall sleeve. Install and tighten seal per manufacturer's instructions.

3.7 TESTING

A. Test all pipelines for water/gas tightness as specified in the Piping or System sections. Furnish all labor, testing plugs or caps, pressure pumps, pipe connections, gauges and all other equipment required. Testing shall be performed in accordance with the testing procedure appended to this Section as specified in each Piping or System Section. All testing shall be performed in the presence of the Owner.

B. Repair faulty joints or remove defective pipe and fittings and replace as approved by the

Engineer. Retest.

3.8 DISINFECTION

A. After satisfactory testing, all potable and protected water collection and distributed systems shall be thoroughly disinfected with a solution of not less than 50 parts per million of available chlorine. The disinfecting solution shall be allowed to remain in the system for a period of 3 hours after which time all valves shall be opened and the system shall be flushed with clean water.

B. Water being flushed from structures or pipelines after disinfection with a chlorine residue concentration in accordance with applicable regulations or greater, shall be treated with a dechlorination solution, in a method approved by the Engineer, prior to discharge.

3.9 HYDROSTATIC TEST

A. Scope: This test shall be used to hydrostatically test piping systems for structural integrity and leaks. The test shall be performed at ambient temperature unless otherwise specified.

B. Test Fluid

Bid Set April 2017



1. Water should be used as the test fluid whenever possible. In those systems where water cannot be used the test fluid may be either the one to be used in the system or the one agreed upon by the Engineer and the Contractor.

C. Test Equipment

1. Water - Of sufficient capacity to deliver the required test pressure.

2. Strainer - On inlet side of the pump to prevent foreign matter from entering the system.

3. Valves - Shall be provided on the suction and discharge side of the pump.

4. Heater - To allow heating of the test fluid when elevated temperatures are required for test.

5. Relief Valve - Set at a pressure to relieve at 20 to 25 percent above the required test pressure.

6. Pressure Gauge(s) - Capable of reaching 50 percent over the test pressure. These should be located at the pump discharge and any other place deemed convenient by the Contractor.

7. Pressure gauges and relief valves shall be checked for accuracy before use in test procedures.

D. Preparation for Test

1. Determine the fluid to be used for the test, and, if other than ambient temperature is required, what the test temperature will be.

2. When a fluid other than water is used for a test, the equipment used for the test shall be of a material compatible with the test fluid. Normally this would be equal to the piping material.

3. Vents shall be provided at the high points of the system and drains provided where means of venting or draining do not exist.

4. Remove or block off, all relief valves, rupture discs, alarms, control instruments, etc., that shall not be subjected to the test pressure.

5. All discs, balls, or pistons from check valves shall be removed if they interfere with filling of the system. Open all valves between inlet and outlet of the section to be tested.

6. Connect pump and provide temporary closures for all of the external openings in the system. Use caution to ensure that the closures are properly designed and strong enough to withstand the test pressure.

7. All joints, including welds, are to be left uninsulated and exposed for examination during test.

Bid Set April 2017



8. A joint previously tested in accordance with this Section may be covered or insulated.

9. Piping designed for vapor or gas shall be provided with additional temporary supports, if necessary, to support the weight of the test liquid.

10. Expansion joints shall be provided with temporary restraint for additional pressure under test or shall be isolated from the test.

11. Flanged joints, where blanks are inserted to isolate equipment during the test, need not be tested.

E. Test Pressure

1. The hydrostatic test pressure shall be 1-1/2 times the design pressure unless otherwise specified in the System Section.

F. Test Procedure

1. Allow the test fluid to enter the system. Open vents to allow displacement of all entrapped air. For all pipelines exceeding 500-ft in length, the maximum rate of filling shall be limited to that which produces a maximum nominal flow velocity of one foot per second in the pipe to be tested.

2. Close vents and restrict personnel in the test area to those involved in the test.

3. Raise the pressure slowly with the pump until the predetermined test pressure is reached. Maintain pressure for duration of time specified in System Section, keeping personnel at a safe distance.

4. Reduce the pressure about 20 percent and hold it at that point while the entire system is carefully inspected for leaks, cracks, or other signs of defects.

5. If defects are found, the pressure shall be released, the system drained, the defects corrected and the test repeated.

6. After a satisfactory test has been completed, the line shall be drained.

G. Flushing

1. Lines tested with water shall be completely drained.

2. Lines shall be flushed, after test.

H. Test Records

1. Records shall be maintained of all tests performed.

2. Test records shall include:

a. Date of Testing

b. Identification of Piping Tested

c. Test Fluid

d. Test Pressure

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e. Signature of Contractor

f. If leaks are found, they shall be noted, on the record. After correction,

retesting as specified for original test.

3. Records of test shall be maintained by the Contractor and minimum of 4 copies furnished to the Engineer.

END OF SECTION

Bid Set April 2017




Bid Set April 2017

Stainless Steel Pipe and Fittings 15066-1


SECTION 15066 STAINLESS

STEEL PIPE AND FITTINGS

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and install, test, complete and ready for operation all stainless-steel pipe as shown on the Drawings and as specified herein.

B. Where the word "pipe" is used, it shall refer to pipe, fittings, hangers, supports and

appurtenances unless otherwise noted.

C. The work includes, but is not necessarily limited to:

1. Furnishing and installing above grade, stainless steel pipe, fittings and specials with screwed, butt welded, or flanged and plain ends.

1.2 RELATED WORK

A. Concrete work is included in Division 3.

B. Valves and appurtenances are included in Section 15100.

C. Piping specialties are included in Section 15120.

D. Pipe hangers and supports are included in Section 15140.

1.3 SUBMITTALS

A. Submit, in accordance with Section 01300, the following:

1. Within 30 calendar days following effective date of the Agreement submit the name of the pipe, fitting and appurtenances manufacturers and a list of the material to be furnished by each manufacturer.

2. Shop drawings including piping layouts and schedules, including dimensioning, fittings, expansion joints, locations of valves and appurtenances, joint details, wall penetration details, methods and locations of supports and all other pertinent technical specifications for all piping to be furnished. Shop drawings shall include all data and information required for the complete piping systems. All dimensions shall be based on the actual equipment to be furnished. Types and locations of pipe hangers and/or supports shall be shown on the piping layouts for each pipe submittal. Not all dimensions will be checked by the Engineer, nor will detailed review be performed. Contractor shall be responsible for accurate dimensioning of piping systems.

Bid Set April 2017



3. Proposed cleaning method, including pre-cleaning, descaling, chemicals to be used, or mechanical descaling method and final cleaning/passivation

4. Certifications that welders are qualified, in accordance with ANSI B31.1, Paragraph 127.5 for shop and project site welding of pipe work.



1. ASTM A312 - Standard Specification for Seamless and Welded Austenitic Stainless Steel Pipes.

2. ASTM A530 - Standard Specification for General Requirements for Specialized Carbon and Alloy Steel Pipe.

3. ASTM A778 - Standard Specification for Welded, Unannealed Austenitic Stainless Steel Tubular Products.

B. American National Standards Institute (ANSI):

1. ANSI B16.1 - Cast Iron Pipe Flanges and Flanged Fittings Classes 25, 125 and 250.

2. ANSI B16.9 - Factory-Made Wrought Steel Buttwelding Fittings.

3. ANSI B36.19 - Stainless Steel Pipe.

C. American Water Works Association (AWWA):


D. American Society of Mechanical Engineers (ASME):

1. ASME B31.1 - Power Piping.

E. American Welding Society (AWS):

F. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.


A. Stainless steel pipe and fittings shall be furnished by a single manufacturer who is fully experienced, reputable, qualified and regularly engaged for the last 5 years in the manufacture of the materials to be furnished. The pipe and fittings shall be designed, constructed and installed in accordance with the best practices and methods and shall comply with this Section.

Bid Set April 2017




A. Piping shall be installed in those locations as shown on the Drawings.

B. The equipment and materials specified herein are intended to be standard types of stainless steel pipe and fittings for use in transporting stormwater.

C. Stainless steel piping for the system listed below shall be designed for the following conditions:

1. System: Sample piping and pipeline drain.

a. Material: Type 316L.

b. Operating Pressure: Varies.

c. Test Pressure: 25 psig.

d. Flow Velocity: Varies.

e. Temperature: Varies.


A. Care shall be taken in loading, transporting and unloading to prevent injury to the pipe and fittings. Pipe and fittings shall not be dropped. Pipe and fittings shall be examined before installation and no piece shall be installed which is found to be defective.

B. In handling the pipe, wide cushioned slings or other devices and methods acceptable to the Engineer shall be used. No uncushioned ropes, chairs, wedges or levers shall be used in handling the pipe, fittings and couplings.

C. If any defective pipe is discovered after it has been installed, it shall be removed and replaced with a sound pipe by the Contractor, at the Contractor's own expense. All pipe and fittings shall be thoroughly cleaned before installation and shall be kept clean until they are put into service.

PART 2 PRODUCTS

2.1 MATERIALS

A. Stainless steel pipe and fittings 6-in and less shall be fabricated from stainless steel sheet and conform to ASTM A778 Type 316L. Carbon content of Type 316L material shall be 0.03 percent maximum. Finish shall be No. 1 or No. 2B.

B. Pipe shall be die-formed or rolled true to dimension and round. Tolerances for length, inside and outside diameter and straightness shall conform to ASTM A530. The two edges of sheet shall be brought to line so as not to leave a shoulder on the inside of the pipe. Ends of pipe and fittings shall be perpendicular to the longitudinal axis. Longitudinal seams on pipe and fittings shall be welded by either the tungsten gas or the metallic-gas method. The interior welds shall be smooth, even and shall not have an internal bead higher than 1/16-in. All pieces shall be marked with gauge and type of

Bid Set April 2017



stainless steel and with the initials of the inspector marked on the inside of each piece, at each end.

C. Pipe and fittings shall be supplied with the following minimum wall thickness: 12 Gauge.

D. Fittings shall be smooth curve type up to 18-in diameter and mitered type 20-in diameter and greater. Fittings shall conform to ANSI B16.9.

E. Flanges for pipe 4-in and smaller shall be of the type of stainless steel as the pipeline, and shall be welded directly to the pipe end, and shall be drilled to the 125 lb ANSI B16.1 standard. Flanges for pipe larger than 4-in shall have stub ends or rolled angle rings of the type of stainless steel as the pipeline welded to the pipe end, with suitable gaskets between the mating surfaces and joined through the use of 125 lb rated backup flanges, drilled to ANSI B16.1, and made of Type 316 stainless steel Where the pipe stub is to pass through a sleeve during installation, a split-type back up flange shall be used. Bolts, washers, nuts and other hardware for flange bolting shall be Type 316 stainless steel.

F. Gaskets for flanged connections shall be a minimum of 1/16-in thick and shall be Viton.

G. Shop fabricated multiple output headers may be used in lieu of individual flanged fittings.

H. Wall pipes shall have integral shop welded wall stops.

I. All stainless-steel pipe and fittings shall be pickled at the point of manufacture, scrubbed and washed until all discoloration is removed in accordance with ASTM A380.

J. Shop welding of fabrications shall be done according to the procedures and by welders certified per ASME Section IX. Welds shall be by an inert gas shielding process using only extra low carbon filler metals. Welds shall have a bead height of no more than 1/16-in. Butt welds shall have 100 percent penetration to the interior or backside of the weld joint. Cross-sectional thickness of welds shall be equal or greater than that of the parent metal.

K. Where shown on the Drawings or where approved by the Engineer, plain end pipe shall be joined by all stainless steel flexible couplings. Sleeve type couplings shall be of the Type 316L stainless steel and shall be Style 38 as manufactured by Dresser Manufacturing Division of Dresser Industries; coupling 411 as manufactured by Smith Blair, Inc. or equivalent couplings manufactured by Depend-O-Lok Co.

L. Where shown on the Drawings or where approved by the Engineer, flanged coupling adaptors shall be used to connect plain end pipe to equipment, fittings and valves. Flanged coupling adaptors shall be of the Type 316L stainless steel and shall comply with AWWA C207. Flanged coupling adapters shall be manufactured by Dresser Manufacturing Division of Dresser Industries; Smith Blair, Inc. or equal.

Bid Set April 2017



PART 3 EXECUTION

3.1 INSTALLATION

A. Pipe and fittings shall be installed true to grade and alignment and pipe anchorage and/or restraint shall be provided where required. Manufacturer's instructions shall be strictly followed.

B. Pipe and fittings shall be protected from dirt, dust, oil, grease and other foreign matter during installation to prevent damage to pipe and to assure no foreign matter is left in the piping.

C. To assemble the joints in the field, thoroughly clean all joint surfaces and gaskets, if any, with soapy water before assembly. Bolts shall be tightened alternately, evenly to the manufacturer's specified torques. Under no condition shall extension wrenches or pipe-over-handle ratchet wrenches be used to secure greater leverage. All electrical bonding or insulation shall be installed as joints are made up.

D. Fittings, in addition to those shown on the Drawings, shall be provided if required. Due consideration shall be given to thermal expansion/contraction over a temperature range of 200 degrees F.

E. When cutting of pipe is required, the cutting shall be done by machine neatly, without damage to the pipe. Cut ends shall be smooth and at right angles to the axis of the pipe.

F. After installation, stainless steel pipe lines shall be washed clean with steam or hot

water to remove any foreign material picked up during transport.

3.2 JOINING MECHANICAL AND RESTRAINED JOINTS

A. Mechanical joints shall be in accordance with the "Notes on Methods of Installation" under AWWA C111 and the instructions of the manufacturer.

B. Restrained joint pipe and fittings shall be installed in the locations shown on the Drawings and as acceptable to the Engineer.

3.3 JOINING FLANGED JOINTS

A. Flanged joints shall be made with gasket, bolts and nut bolts stud with a nut on each end, or studs with nuts where the pipe is tapped. The number and size of bolts shall conform to the same standard requirements as the flange.

3.4 FIELD WELDING

A. Welding in the field shall be done only if approved by the Engineer. Field welds shall be made by welders certified under ASME Section IX and be equal in all respects to shop welds. After field welding has been done, all joints shall be thoroughly cleaned and buffed using deburring and finishing wheels.

Bid Set April 2017



3.5 FIELD PAINTING

A. Final field painting is included in Section 09902 except that for all stainless-steel pipe, only bands, labels and arrows rather than full pipe painting will be required.

3.6 DISINFECTION AND CLEANUP

A. After installation, completed lines shall be cleaned with Oakite deoxidizer or similar deoxidizer as recommended by the manufacturer to remove all foreign matter, construction stains or shop markings. Cleaned lines shall be rinsed clear with steam or hot water.

END OF SECTION

Bid Set April 2017

Ductile Iron Pipe and Fittings 15072 - 1


SECTION 15072

DUCTILE IRON PIPE AND FITTINGS

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required, install, and test ductile iron pipe and fittings for plant mechanical piping as shown on the Drawings and as specified herein.

B. Mechanical piping shall include all piping and fittings installed above grade, in utility tunnel or gallery and shall exclude pipe in valve vaults, manholes, cleanouts and similar yard structures.

C. Mechanical piping shall be installed as shown on the Drawings. Provide pipe supports, hangers and couplings as required to achieve a complete pipe system.

D. Where the word "pipe" is used, it shall refer to pipe, fittings, or appurtenances unless otherwise noted.

1.2 RELATED WORK

A. Delivery, Storage and Handling is included in Section 01600.

B. Yard Piping is included in Section 02616.

C. Painting is included in Section 09901and Section 09902.

D. General Piping Requirements are included in Section 15050.

E. Valves are included in Section 15100.

F. Piping Specialties are included in Section 15120.

G. Pipe Hangers and Supports are included in Section 15140.

1.3 SUBMITTALS

A. Submit, in accordance with Section 01300, shop drawings and product data required to establish compliance with the Section. Submittals shall include the following

1. Tabulated layout drawings showing actual pipe lengths, diameters, fittings and appurtenances.

2. Prior to shipment of pipe, submit a certified affidavit of compliance from the pipe manufacturer stating that the pipe, fittings, gaskets, linings and exterior coatings for this project have been manufactured and tested in accordance AWWA and ASTM standards and requirements specified herein.

Bid Set April 2017







1. ANSI B1.1 - Unified Inch Screw Threads (UN and UNR Thread Form).

2. ANSI B16.1 - Cast Iron Pipe Flanges and Flanged Fittings Classes 25, 125 and 250.

3. ANSI B18.2 - Square and Hex Bolts and Screws Inch Series Including Hex Cap Screws and Lag Screws.

C. American Water Works Association (AWWA):

1. AWWA C104 - Cement-Mortar Lining for Ductile-Iron Pipe and Fittings.

2. AWWA C110 - Ductile-Iron and Gray-Iron Fittings. (3-in Through 48-in (80mm Through 1200mm) for Water).


4. AWWA C115 - Flanged Ductile-Iron Pipe with Ductile-Iron or Gray-Iron Threaded Flanges.

5. AWWA C116 - Protective Fusion-Bonded Epoxy Coatings for the Interior and Exterior Surfaces of Ductile-Iron and Gray-Iron Fittings.

6. AWWA C150 - Thickness Design of Ductile-Iron Pipe.

7. AWWA C151 - Ductile-Iron Pipe, Centrifugally Cast.

8. AWWA C153 - Ductile-Iron Compact Fittings for Water Service.

9. AWWA C600 - Installation of Ductile-Iron Water Mains and Their Appurtenances.


11. AWWA C651 - Disinfecting Water Mains.



A. Each length of ductile iron pipe supplied for the project shall be hydrostatically tested at the point of manufacture to 500 psi for a duration of 10 seconds per AWWA C151. Testing may be performed prior to machining bell and spigot. Failure of ductile iron

Bid Set April 2017



pipe shall be defined as any rupture of the pipe wall. Certified test results shall be furnished in duplicate to the Engineer prior to time of shipment.

B. Ductile iron pipe and fittings to be installed under this project shall be inspected and tested at the foundry as required by the standard specifications to which the material is manufactured. Furnish in duplicate to the Engineer sworn certificates of such tests and their results prior to the shipment of the pipe.

C. Pipe and fittings to be installed under this Contract may be inspected at the plant for compliance with this Section by an independent testing laboratory selected by the Owner, at the Owner's expense.

D. Inspection of the pipe and fittings will also be made by the Engineer or representative of the Owner after delivery. The pipe shall be subject to rejection at any time on account of failure to meet any of the specified requirements, even though sample pipes may have been accepted as satisfactory at the place of manufacture. Pipe rejected after delivery shall be marked for identification and shall be removed from the job.

E. Pipe and fittings shall be permanently marked with the following information:

1. Manufacturer, date.

2. Size, type, class, or wall thickness.

3. Standard produced to (AWWA, ASTM, etc.).


A. See Section 01600 for general requirements.

B. Care shall be taken in loading, transporting and unloading to prevent injury to the pipe or coatings. Under no circumstances shall the pipe be dropped or skidded against each other. Slings, hooks, or pipe tongs shall be padded and used in such a manner as to prevent damage to the exterior surface or internal lining of the pipe.

C. Materials, if stored, shall be kept safe from damage. The interior of all piping, fittings and other appurtenances shall be kept free from dirt or foreign matter at all times.

D. Pipe ends including flange faces shall be protected from damage. All openings shall be adequately covered with a minimum 1/2 inch thick wooden blind flange secured in place with steel fasteners or end-caps/plugs be put on pipes to prevent entrance of dirt, water and debris, and keep the pipe interior clean.

E. Pipe shall not be stacked higher than the limits recommended by its manufacturer. The bottom tier shall be kept off the ground on timbers, rails, or concrete. Stacking shall conform to manufacturer's recommendations.

Bid Set April 2017



PART 2 PRODUCTS

2.1 MATERIALS

A. Pipe:

1. Ductile iron pipe shall conform to AWWA C115 and C110. Flanged and groove end pipe shall be Thickness Class 53 as per AWWA C150.

2. Pipe shall be supplied in standard lengths as much as possible.

3. Ductile iron pipe shall be as manufactured by U.S. Pipe and Foundry Company, Inc.; American Cast Iron Pipe Company; Clow Water System Company, or equal.

B. Joints:

1. Ductile iron pipe shall have flanged or grooved joints. Flange shall be flat face type, unless otherwise noted, meeting ANSI requirements ANSI B16.1 Class 125.

2. Flange gasket shall be full face type Viton per AWWA C111 to provide positive sealing for the flanged ductile iron joints. Thickness shall be 1/8-in unless otherwise indicated. The gasket materials for potable water pipe shall be certified by NSF61.

3. Assembly bolts shall be square headed carbon steel machine bolts with hexagon nuts per ANSI B18.2. Thread shall conform to ANSI B1.1. Bolt length shall be such that after joints are assembled, the bolts shall protrude through the nuts, but not more than 1/2-in. Steel flanges in conformance with AWWA C207, Class D, may be mated to iron valves, fittings, or other parts having either integral Class 125 iron flanges or screwed Class 125 companion flanges. When such construction is used, the raised face on mating flanges shall be removed.

4. Grooved joints shall conform to AWWA C606 standard rigid couplings and shall be Style 31 couplings as manufactured by Victaulic, Anvil International, or approved equal.

a. For direct connection of ductile pipe to steel pipe of IPS sizes: Victaulic Style 307

transition coupling with offsetting, angle-pattern, bolt pads.

b. Grooved end fittings for AWWA ductile iron pipe shall conform to ANSI A21.10/AWWA C110 for center-to-end dimensions and ANSI A21.10/AWWA C110 or AWWA C153 for wall thickness, with AWWA C606 grooved ends.

5. Sleeve type couplings shall be Dresser Style 38 or 138 as manufactured by Dresser Industries, or equivalent products of Smith-Blair, Romac Industries, Ford Meter Box Co. or approved equal as specified in Section 15120.

6. Flanged coupling adaptors and dismantling joints shall be as specified in Section 15120.

Bid Set April 2017



C. Fittings:

1. Pipe fittings shall be ductile iron with a pressure rating of 250 psi. Fittings shall meet the requirements of AWWA C110 as applicable. Fittings shall have the same pressure rating, as a minimum, of the connecting pipe.

D. Weld-on/Welded-on Outlets

1. The Manufacturer shall have the capability to furnish welded-on outlets as a radial (tee) outlet, tangential outlet, or lateral outlet fabricated at a specific angle to the main line pipe (in 15º increments between 45º and 90º from the axis of the main line pipe) as indicated on the Drawings. Welded-on outlets shall be fabricated by the pipe manufacturer at the same facility where the pipe is produced. The pipe manufacturer shall have a minimum of 5 years experience in the fabrication and testing of outlets of similar size and configuration.

2. Outlet Joint Types: The joints on welded-on branch outlets shall meet, where applicable, the requirements of AWWA C111 and/or AWWA C115.

3. Design:

a. The pipe wall thickness and weld reinforcement design for welded-on outlet

fabrications shall be based on a method similar to that which is described in Section 13 of AWWA Manual M11 for similar welded outlets on steel pipe (which in turn refers to Section VIII of the ASME Unfired Pressure Vessel Code for design method details). Reinforcing welds shall be placed using Ni- Rod FC 55 cored wire, Stoody Castweld Ni 55-0 cored wire, or Ni-Rod 55 electrodes manufactured by INCO Alloys (or an electrode with equivalent performance properties). Carbon steel electrodes are not acceptable. Upon request, the Manufacturer shall provide test results indicating typical physical properties of the utilized weld material (an all-weld sample) as well as typical physical properties from transverse tensile and impact specimens machined from Butt-weld joined ductile iron pipe coupons to show the suitability or equivalence of the electrodes used.

b. Parent pipe and branch outlet candidate pipe shall be centrifugally cast ductile

iron pipe designed in accordance with AWWA C150 and manufactured in accordance with AWWA C151. Minimum classes for parent and outlet pipe shall be: for sizes 4-inch through 54-inch, Special Thickness Class 53; for sizes 60-inch through 64-inch, Pressure Class 350.

c. All welded-on outlets 4-inch through 30-inch shall be rated for a working pressure

of 250 psi. Welded-on outlets 36-inch and larger shall be rated for 200 psi. Welded-on outlets of all diameters and configurations must have a minimum safety factor of 2.0 based on proof of design hydrostatic test results. The Manufacturer shall, at the request of the Owner or the Engineer, provide representative proof test data confirming the design, hydrostatic test results, and safety factors.

Bid Set April 2017



d. Prior to the application of any coating or lining in the outlet area, all weldments for branch outlets to be supplied on this project shall be subjected to an air pressure test of at least 15 psi. Air leakage is not acceptable. Any leakage shall be detected by applying an appropriate foaming solution to the entire exterior surface of the weldment and adjoining pipe edges or by immersing the entire area in a vessel of water and visually inspecting the weld surface for the presence of air bubbles. Any weldment that shows any signs of leakage shall be repaired and re-tested in accordance with the Manufacturers' written procedures.

E. Interior Lining:

1. Ductile iron pipe and fittings shall have the same type of lining as specified.

2. Ductile iron pipe and fittings shall be lined with a ceramic-filled amine-cured epoxy, Protecto 401 by Induron. The lining thickness shall be 40 mils minimum. Application shall be performed by an applicator approved by the coating manufacturer, in accordance with manufacturer's instructions and under controlled conditions at the applicator's shop or the pipe manufacturer's plant. Applicator shall submit a certified affidavit of compliance with manufacturer's instructions and requirements specified herein.

3. Interior linings for potable water use shall be certified by NSF 61.

F. Exterior Coatings:

1. Unless otherwise specified, all coatings shall be shop applied with "hold-backs" provided as required at pipe and fitting ends for satisfactory installation for joint connections in the field. Provide all necessary coating materials to perform field coating applications at joints. Unless otherwise noted, field applied coating material shall be compatible with or equal to the shop applied material. Field repair of pipe with damaged coating shall receive prior approval of the Engineer. If, in the opinion of the Engineer that the coating damage is beyond repair the pipe shall be replaced at the expense of the Contractor. All flange bearing surfaces shall be uncoated.

2. Unless otherwise specified, all exposed exterior ferrous surfaces shall be painted with an applicable paint system as specified under Division 9. Surface preparation and application thereof shall be in conformance with applicable provisions of Division 9.

G. Pipe Hangers and Supports:

1. Pipe hangers and supports shall be provided at suitable distance along the pipeline regardless whether they are shown or not shown on the Drawings.

2. Pipe hangers and supports shall be as specified in Section 15140.

Bid Set April 2017



PART 3 EXECUTION

3.1 PIPE INSTALLATION

A. General

1. Piping and fittings shall be installed true to alignment and rigidly supported. Anchorage shall be provided where required. Any damage to linings shall be repaired to the satisfaction of the Engineer before the pipe is installed. Each length of pipe shall be cleaned out before installation. All of manufacturer's recommendations shall be complied with.

2. Deflection at joints shall not exceed that recommended by the pipe manufacturer. Fittings, in addition to those shown on the Drawings, shall be provided, if required, in areas where conflict exists with the existing facilities.

3. When pipe cutting is acceptable to the Engineer, the cutting shall be done by abrasive saw, leaving a smooth cut at right angles to the axis of the pipe. Any damage to the lining shall be repaired to the satisfaction of the Engineer. Field cut ends shall be sealed with approved epoxy coating in accordance with manufacturer's instructions.

4. Ductile iron and fittings shall be installed in accordance with requirements of AWWA C600 modified.

B. Jointing

1. Flanged joints shall be made using gaskets, bolts, bolt studs with a nut on each end, or studs with nuts where the flange is tapped. The number and size of bolts shall conform to the same ANSI Standard as the flanges.

2. Bolts in flanged joints or mechanical joints shall be tightened alternately and evenly.

3. Sleeve type couplings and grooved joints using split ring couplings shall be installed in accordance with the procedures recommended by their respective manufacturers.

C. Pipe and appurtenances connected to equipment shall be supported in such a manner as to prevent any strain being imposed on the equipment. When manufacturers have indicated requirements that piping loads shall not be transmitted to their equipment, submit a certification stating that such requirements have been complied with.

D. Sleeves of proper size shall be installed for all pipes passing through floors or walls. Sleeves shall be installed as shown on the Drawings. Where indicated on the Drawings or required for liquid or gas-tightness, the pipe shall be sealed with a mechanical seal similar to Link-Seal as manufactured by Thunderline Corporation, or equal.

E. Sleeves and wall pipes shall have thrust collar located at the mid-depth of wall.

Bid Set April 2017



F. Concrete inserts for hangers and supports shall be furnished and installed as recommended by the manufacturer as shown on the Drawings or as specified herein. The inserts shall be set in accordance with the requirements of the piping layout and their locations verified from approved piping layout drawings and the structural drawings.

G. Pipelines supported by pipe hangers from the ceiling, or otherwise supported where lateral displacement of pipe is probable, shall be seismically braced laterally at spacing determined in pipe support system design as specified in Section 15140 and herein and braced longitudinally and laterally at spacing determined in pipe support system design as specified in Section 15140 and herein and at 90 degree bends. The seismic bracing, as a minimum, shall consist of 3/8-in steel plate welded to pipe hanger, 1/2-in diameter all threaded rod, 1/2-in diameter flexible connector and eye rod inserted in the ceiling. Submit seismic loading and calculations for Engineer's review.

3.2 TESTING

A. Piping shall be subject to acceptance tests. Provide all necessary utilities, labor and equipment for flushing and testing and dispose all waste after the test including water.

B. Pipe and fittings shall be pressure tested using water to 1.5 times the working pressure for one hour and the pipeline shall show no leakage.

C. Correct any leakage and repair any damage to the pipe and pipe appurtenances or to any structures resulting from, or caused by tests. All leaks shall be repaired and lines retested.

3.3 CLEANING

A. Clean the pipe by flushing with water or other means to remove all dirt, stones, pieces of wood, or other material which may have entered during the construction period. All debris shall be removed from the pipeline. The lowest segment outlet shall be flushed last to assure debris removal.

3.4 PIPE MARKING

A. Exposed piping, exterior and interior, shall be identified by painted legend markers, directional arrow markers and number markers as required. Pipe marking colors shall contrast with pipe color for ease of visibility. Pipe marking shall match the existing markings. Letters and markers 1-1/8-inches in width shall be installed on pipes under 3-in in diameter. Markers 2-1/2-inches in width shall be installed on pipes 3-inches in diameter and larger. Legend markers, directional arrow markers and number markers shall be placed as directed by the Engineer. Markers shall be located where pipes pass through walls or floors, at piping intersections and maximum 15-ft spacing on piping runs.

B. Pipe marker letter legend shall be as follows:

Service Fluid Pipe Marker Legend WWF: Stormwater WWF DISCH

END OF SECTION

Bid Set April 2017

Valves 15100 - 1


SECTION 15100

VALVES

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and install complete and ready for operation and test all non-buried valves as shown on the Drawings and as specified herein.

B. The equipment shall include, but not be limited to, the following; however not all items specified herein may be included in this project.

1. General Requirements.

2. Valve Actuators - Manual.

3. Gate Valves.

4. Check Valves.

5. Ball Valves.

6. Corporation Stops.

7. Air Release Valves, Vacuum Relief Valves and Combination Valves.

1.2 RELATED WORK

A. Buried valves and appurtenances are included in Division 2.

B. Piping and disinfection for potable water systems is included in the respective Sections of Divisions 2.

C. Shop and Finish painting is included in Sections 09901 and 09902.

D. Instrumentation, not specified herein, is included in Division 13.

E. Submersible Solids Handling Pumps are included in Section 11306.

F. Electrical work is included in Division 16.

G. Certain items similar to those specified in this Section may be specified to be furnished and installed with individual equipment or systems. In case of a conflict, those individual equipment or system requirements shall govern.

H. Valve operators shall be mounted at factory on valves as specified herein, as part of the work of this Section.

Bid Set April 2017

Valves 15100 - 2


I. Pipeline appurtenances are included in Section 15120 and include the following:

1. Unions.

2. Flanged Joints.

3. Dielectric Connectors.

4. Plugs and Caps.

5. Miscellaneous Adaptors.

6. Vents and Drains.

7. Service Clamps.

8. Quick Connect Couplings.

9. Mechanical Sleeve Seals.

10. Flexible Connectors.

11. Expansion Joints.

12. Harnessing and Restraints.

13. Pipe Cleaning Equipment.

14. Appurtenances and Miscellaneous Items.

15. Color Coding and Labeling.

1.3 SUBMITTALS

A. Submit to Engineer, in accordance with PR-9, materials required to establish compliance with this Section. First submittal shall be valve schedule described in Paragraph 1.09. Approval of valve schedule submittal is required prior to Contractor submitting any of equipment in this specification. Subsequent Equipment Submittals shall include at least the following:

1. Valve tag number.

2. Manufacturer and supplier.

3. Address at which equipment will be fabricated or assembled.

4. Drawings showing assembly details, materials of construction and dimensions.

5. Descriptive literature, bulletins and/or catalogs of the equipment.

6. Total weight of each item.

Bid Set April 2017

Valves 15100 - 3


7. A complete bill of materials.

8. Additional submittal data, where noted with individual pieces of equipment.

B. Test Reports:

1. Provide certified hydrostatic test data, per manufacturer's standard procedure or MSS-SP-61 for valves.

C. Certificates:

1. For each valve specified to be manufactured, tested and/or installed in accordance with AWWA and other standards, submit an affidavit of compliance with appropriate standards, including certified results of required tests and certification of proper installation.

D. Manufacturer's Installation and Application Data.

E. Operating and Maintenance Data.

1. Operating and maintenance instructions shall be furnished to Engineer as provided in PR-26 and PR-27. Instructions shall be prepared specifically for this installation and shall include required cuts, drawings, equipment lists, descriptions and other information required to instruct operating and maintenance personnel unfamiliar with such equipment.


A. ASTM International:

1. ASTM A48 - Standard Specification for Gray Iron Castings.

2. ASTM A126 - Standard Specification for Gray Iron Castings for Valves, Flanges and Pipe Fittings.

3. ASTM A240 - Standard Specification for Heat-Resisting Chromium and Chromium- Nickel Stainless Steel Plate, Sheet and Strip for Pressure Vessels.

4. ASTM A276 - Standard Specification for Stainless Steel Bars and Shapes.

5. ASTM A436 - Standard Specification for Austenitic Gray Iron Castings.


7. ASTM B30 - Standard Specification for Copper-Base Alloys in Ingot Form.

8. ASTM B62 - Standard Specification for Composition Bronze or Ounce Metal Castings.

Bid Set April 2017

Valves 15100 - 4


B. American Water Works Association (AWWA):


2. AWWA C500 - Metal-Seated Gate Valves Supply Service.

3. AWWA C504 - Rubber-Seated Butterfly Valves.

4. AWWA C507 - Ball Valves, 6-in through 48-in (150mm through 1200mm).

5. AWWA C508 - Swing-Check Valves for Waterworks Service, 2-in (50mm through 24-in (600mm) NPS.

6. AWWA C509 - Resilient-Seated Gate Valves for Water Supply Service.

7. AWWA C511 - Reduced-Pressure Principle Backflow-Prevention Assembly.

8. AWWA C540 - Power-Actuating Devices for Valves and Sluice Gates.

9. AWWA C541 - Hydraulic and Pneumatic Cylinder and Vane Type Actuators for Valves and Slide Gates.

10. AWWA C550 - Protective Epoxy Interior Coatings for Valves and Hydrants.

11. AWWA C800 - Underground Service Line Valves and Fittings.

C. American National Standards Institute (ANSI):

1. ANSI B1.20.1 - Specifications, Dimensions, Gauging for Taper and Straight Pipe Threads (except dry seals).

2. ANSI B16.1 - Cast Iron Pipe Flanges and Flanged Fittings.

3. ANSI B16.10 - Face-to-Face and End-to-End Dimensions of Valves.

D. American Iron and Steel Institute (AISI).

E. Manufacturer's Standardization Society of the Valve and Fittings Industry (MSS):

1. MSS-SP-61 - Pressure Testing of Steel Valves.

2. MSS-SP-70 - Cast Iron Gate Valves, Flanged and Threaded Ends.

3. MSS-SP-71 - Cast Iron Swing Check Valves, Flanges and Threaded Ends.

4. MSS-SP-72 - Ball Valves with Flanged or Butt-Welding Ends for General Services.

5. MSS-SP-78 - Cast Iron Plug Valves, Flanged and Threaded Ends.

6. MSS-SP-80 - Bronze Gate, Globe, Angle and Check Valves.

Bid Set April 2017

Valves 15100 - 5


7. MSS-SP-82 - Valve Pressure Testing Methods.

8. MSS-SP-98 - Protective Coatings for the Interior of Valves, Hydrants and Fittings.

F. National Electrical Manufacturers Association (NEMA).

G. Underwriters Laboratories (UL).

H. Factory Mutual (FM).

I. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.


A. Qualifications:

1. Valves and appurtenances shall be products of well established firms who are fully experienced, minimum ten years, reputable and qualified in manufacture of particular equipment to be furnished.

2. Equipment shall be designed, constructed and installed in accordance with best practices and methods and shall comply with this Section as applicable.

3. Units of the same type shall be the product of one manufacturer.

B. Certifications:

1. Manufacturers shall furnish an affidavit of compliance with Standards referred to herein as specified in Paragraph 1.03C above. Refer to Part 3 for testing required for certain items in addition to that required by referenced standards.

C. Provide services of a qualified and factory-trained service representative of manufacturer to provide operational and maintenance instruction, for a one day, eight-hour period for each type of the following equipment:

1. Air release, air and vacuum valves.

2. Check valves.

3. Gate valves.

D. Inspection of units may also be made by Engineer or other representative of Owner after delivery. Equipment shall be subject to rejection at any time due to failure to meet any of specified requirements, even though submittal data may have been accepted previously. Equipment rejected after delivery shall be marked for identification and shall be removed from job site at once.

Bid Set April 2017

Valves 15100 - 6



A. Equipment and materials specified herein are intended to be standard for use in controlling flow of stormwater as noted on Drawings.

B. Valves, appurtenances and miscellaneous items shall be installed as shown on Drawings and as specified, so as to form complete workable systems.


A. Reference is made to Section 01600 for additional information.

B. Packing and Shipping:

1. Care shall be taken in loading, transporting and unloading to prevent injury to the valves, appurtenances, or coatings. Equipment shall not be dropped. Valves and appurtenances shall be examined before installation and no piece shall be installed which is found to be defective. Damage to the coatings shall be repaired as acceptable to Engineer.

2. Prior to shipping, ends of valves shall be acceptably covered to prevent entry of foreign material. Covers shall remain in place until after installation and connecting piping is completed.

a. Valves 3-in and larger shall be shipped and stored on site until time of use

with wood or plywood covers on each valve end.

b. Valves smaller than 3-in shall be shipped and stored as above except that heavy cardboard covers may be used on the openings.

c. Rising stems and exposed stem valves shall be coated with a protective oil

film which shall be maintained until the valve is installed and put into use.

d. Corrosion in evidence at the time of acceptance by the Owner shall be removed, or the valve shall be removed and replaced.

C. Storage and Protection:

1. Special care shall be taken to prevent plastic and similar brittle items from being directly exposed to the sun, or exposed to extremes in temperature, to prevent deformation. See the individual piping sections and manufacturer's information for further requirements.

1.8 MAINTENANCE

A. Special tools and the manufacturer's standard spare parts, if required for normal operation and maintenance, shall be supplied with the equipment in accordance with PR-26 and where noted, as specified herein. Tools shall be packaged in a steel case, clearly and indelibly marked on the exterior to indicate equipment for which tools are intended.

Bid Set April 2017

Valves 15100 - 7


B. Provide one operations and maintenance manual for each type of valve and operator supplied under this specification in accordance with PR-26 and PR-27.

C. Included within operations and maintenance manuals, provide a list of all spare and replacement parts with individual prices and location where they are available.

1.9 VALVE DESIGNATIONS AND SCHEDULE

A. Valves shall be identified by a unique valve tag as identified in valve schedule prepared by Contractor. Specific type of valve to be used will be identified by symbol and/or call out on Drawings. Contractor shall identify each valve by its assigned tag number on shop drawings and equipment submittals.

B. Contractor shall refer to the P&IDs and mechanical plans for type of each valve called out

by abbreviation or drawing symbol. Prior to first valve submittal, Contractor shall submit a detailed valve schedule listing process valves to be furnished along with Contract Drawing P&IDs edited electronically which shall include valve tag numbers prepared by Contractor identifying each valve. This valve schedule shall NOT include valves furnished under Division 2. Valve schedule shall include: valve tag number; valve designation; valve size; end connections and operator type. Valve tag convention shall be four digits long, numbering shall be linked to the P&ID Sheet on which it is shown. Identical valves in same position in parallel processes (EX. Pump inlet/outlet isolation valves where there are three parallel pumps of same type) shall have same tag number followed by a hyphen and quantifier -1, 2, 3 etc. An excerpt of an EXAMPLE schedule is as follows:

Valve Tag.

Designation Size Ends Operator Notes

1000-1 BFV1 8-in Flanged Gear/Handwheel Extra description as necessary

1000-2 BFV1 8-in Flanged Gear/Handwheel 1005 PV1 6-in Flanged Gear/Handwheel

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT - GENERAL

A. Reference is made to Division 1 for additional requirements, including nameplates, provisions for temporary pressure gauges, protection against electrolysis and anchor bolts.

B. Use of a manufacturer's name and/or model or catalog number is for purpose of establishing standard of quality and general configuration desired.

C. Valves and appurtenances shall be of size shown on the Drawings or as noted and as far as possible equipment of same type shall be identical and from one manufacturer.

D. Valves and appurtenances shall have name of maker, nominal size, flow directional arrows, working pressure for which they are designed and standard referenced, cast in

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raised letters or via riveted stainless steel nameplate upon some appropriate part of the body.

E. Unless otherwise noted, items shall have a minimum working pressure of 150 psi or be of same working pressure as pipe they connect to, whichever is higher and suitable for pressures noted where they are installed.

F. Joints, size and material - unless otherwise noted or required by Engineer:

1. Except where noted, joints referred to herein shall be of same type, nominal diameter, material and with a minimum rating equal to pipe or fittings they are connected to.

2. Valves and appurtenances shall be of same nominal diameter as pipe or fittings they are connected to.

3. Valves exposed to view, or in vaults:

a. Plastic valves in chemical service - solvent cement, or flanged ends.

b. 3-in and smaller - threaded ends- unless noted otherwise herein or on Drawings.

c. 4-in and larger - flanged ends.

G. Provide special adaptors as required to ensure compatibility between valves, appurtenances, and adjacent pipe.

H. No alternative materials will be considered for approval unless complete documentation is provided regarding their satisfactory long-term use in similar conditions; in addition, the consideration of any substitution will be considered only if superiority of proposed materials is the intent of substitution, and only if sufficient evidence is provided to document that superiority.

2.2 VALVE ACTUATORS - GENERAL/ MANUAL

A. Geared actuators shall be suitable for all weather service, with mechanical shaft seals, shall be permanently greased, or shall have provisions for greasing. Actuators for submerged duty shall be so rated (all valves located within stormwater detention basin), with certification by manufacturer for submerged service.

B. Valve manufacturer shall supply, mount, and test all actuators on valves at factory. Valves and their individual actuators shall be shipped as a unit.

C. Unless otherwise noted on Drawings, valves shall be manually actuated; non-buried valves shall have an operating wheel, handle or lever mounted on operator. Unless otherwise noted, operation for valves shall be CCW open.

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Valves 15100 - 9


D. Except as otherwise shown on Drawings or specified herein, valves 3-in diameter or larger, with valve hand wheel center line located 7-ft or more above operating floor, shall be provided with chain wheel operators complete with chain guides and hot dipped galvanized steel chain, which loop within 4-ft of operating floor.

E. Actuators shall be capable of moving valve from full open to full close position and in

reverse and holding valve at any position part way between full open or closed.

F. Each operating device shall have cast on it the word "OPEN" and an arrow indicating direction of operation.

G. Gear Actuators:

1. Unless otherwise noted, gear actuators shall be provided for the following: plug and ball valves larger than 3-in diameter; where specified and/or indicated on Drawings; where manual operator effort is greater than 40 lbs rim pull.

2. Actuators shall be capable of being removed from valve without dismantling the valve or removing valve from the line.

3. Gear actuators for quarter turn valves shall be of worm or helical worm gear type with output shaft perpendicular to valve shaft, having a removable hand wheel mounted on output shaft. Where shown on Drawings, a two-inch cast iron operating nut shall be provided. Actuators shall conform to AWWA C504 except where more stringent requirements are provided hereinafter. Gearing shall be machine cut steel designed for smooth operation. Bearings shall be permanently lubricated, with bronze bearing bushings provided to take thrusts and mechanical shaft seals to contain lubricants. Housings shall be sealed to exclude moisture and dirt, allow reduction mechanisms to operate in lubricant and be constructed of cast iron, ASTM A 126, Grade B, or of ductile iron, ASTM A 536. Gear housing bodies for thermoplastic valves may be cast aluminum or fabricated steel to reduce weight. Gear actuators shall indicate valve position and have adjustable stops.

4. Manual Input torque to produce required valve operating torque for worm and travelling nut gear operators shall not exceed 80 ft-lbs. In addition, hand wheel rim pull shall not exceed 20 lbs for valve sizes up to 12 inches, 40 lbs for valve size between 14 and 20 inches, 60 lbs for valve size 24 and greater. Minimum hand wheel size shall be 8 inches for up to 12-inch valve size, 12 inches for up to 16 inch valve size, 18 inches for up to 20 inch size.

5. Gear actuators for multi turn valves shall be of bevel or spiral bevel type with output shaft perpendicular to valve shaft, having a removable hand wheel mounted on output shaft. Gearing shall be machine cut steel designed for smooth operation. Bearings shall be permanently grease lubricated, with dual anti-friction ball bearings on output shaft and mechanical shaft seals to contain lubricants. Output flange of primary gear reducer shall be designed to meet an appropriate MSS or ISO standard to allow mounting to secondary gear reducer. Ring gear shall ride on ball bearings. Stem nut shall be bronze alloy, shouldered, and ride on needle bearings. Housing components shall be O-ring sealed to exclude moisture and dirt, constructed of cast iron, ASTM A 126, Grade B, or of ductile iron, ASTM A 536.

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Gear housing bodies for thermoplastic valves may be cast aluminum or fabricated steel to reduce weight. Manual operator input effort to the hand wheel shall be a maximum of 30 lbs for operating the valve from full open to full close, under any conditions. Maximum hand wheel size shall be 24-in diameter.

H. Additional valve actuator requirements are included with the individual valve types and as

noted in Paragraph 1.02 above.

I. Position indication and direction of opening arrows shall be embossed, stamped, engraved, etched, or raised castings. Decals or painted indications shall not be allowed.

J. Unless otherwise noted, valves larger than 3-in nominal diameter shall be provided with position indicators at the point of operation.

2.3 GATE VALVES

A. General Requirements:

1. Unless otherwise specified below, these requirements shall apply to gate valves.

2. Gate valves shall meet requirements of AWWA C500, AWWA C509 and AWWA C515 as applicable to type of valve specified.

3. Valves shall be furnished with cast iron bodies with Ni-resistant stainless steel trim furnished with bolted NRS enclosed bonnet, Class 125 flanged end connections and Type 316 stainless steel hardware.

4. Discs shall be wedge type of rubber coated ductile iron construction, metal seated and have non-rising stem.

5. Valves shall be equipped with a handwheel operator.

6. Non-rising stem valves shall utilize a minimum of two O-ring stem seals.

7. Unless otherwise specified, valves shall be rated at or above for the following working water pressures:

Valve Size Pressure (psig) 3-in to 12-in 200 14-in to 30-in 150 36-in and greater as specified

a. Valve bodies shall be hydrostatically tested to at least twice the rated working water pressure. In addition, valves shall be seat-tested, bi-directional at rated working pressure, with seat leakage not to exceed one fluid ounce per inch of valve diameter per hour. Provide certificates of testing.

8. Flanged valves to have face-to-face dimensions per ANSI B16.10 and flanges per ANSI B16.1.

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Valves 15100 - 11


9. Bonnet and packing gland bolts shall be Type 316 stainless steel; packing gland bolts shall have bronze nuts.

10. Valve requirements: Resilient Seated a. Conform to AWWA C509. Also UL and FM approved. b. Internal and external epoxy coating of valve body, including bonnet, per

AWWA C550. c. Gate shall be encapsulated with synthetic rubber. It shall be bonded and

vulcanized in accordance with ASTM D429 Method B. d. No recesses in valve body.

11. Exposed valves 16-in and greater indicated for horizontal stem installation shall be furnished with rollers, tracks and scrapers and enclosed bevel gear grease case.

12. Valves shall be marked per AWWA Standards, including name of manufacturer, valve size, and working pressure and year of manufacture.

13. Unless otherwise indicated, valves 12-in and smaller shall be capable of installation in vertical or horizontal position, and sealing in both directions at rated pressure.

B. Valve Applications:

1. Valves for Wastewater/Stormwater Service: a. Resilient seated wedge design manufactured by American Flow Control;

Kennedy/M&H/Clow Valve; J & S Valve; US Pipe or Mueller.

2.4 CHECK VALVES

A. Rubber Flapper Check Valves: Tag Type RFCV.

1. Body shall be cast iron, ASTM A 126, Class B, or ASTM A 536 Gr 65 Ductile iron, 150 lb flanged. Body shall be fusion bonded epoxy coated. Disc shall be Nylon reinforced EPDM encapsulated steel. Valve body and open disc shall provide full flow at least equal to nominal pipe diameter. Seating surface shall be on a 45- degree angle. Top access port shall be full size, allowing disc removal without removing valve body from pipeline. Disc shall be one piece construction, precision molded with and integral O-ring dealing surface and contain steel and nylon reinforcements in both the flex and central disc areas.

2. Rubber flapper check valves shall be as manufactured by APCO 100R series, Crispin Multiplex Series 500, equal by Val-Matic or equal.

2.5 BALL VALVES: TAG TYPE NOTED BELOW

A. General Service Ball Valves: Tag Type BV1.

1. Valves shall be bronze, resilient seated, full port, threaded two-piece bolted body type valves. Manual valves shall have locking levers. Body and cap shall be of brass, ASTM B 30, ball and stem of Type 316 stainless steel and seats and seals

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Valves 15100 - 12


of glass filled TFE. Balls shall be full floating, non-lubricated. Valve seats shall be easily accessible and replaceable.

2. Valves shall be Jamesbury Series 2000 Style 21 as manufactured by Metso Automation; or equal.

B. V Port Ball Valves (Sampling Point and Drains): Tag Type VPB1.

1. Valves shall be 3 piece, bolted body, soft seat, v-port insert design. End connections shall be flanged, Class 150, ANSI B16.5 or welded. Valves actuator shall be manual for isolation. Valve characteristics shall provide for the operating conditions shown on the Drawings.

2. Body: Type 316 stainless steel; Ball and characterized insert: Type 316 stainless steel

with hard chrome face. Shaft: Type 316 stainless steel, one piece. Seats: Type 316 stainless steel filled PTFE, replaceable; Packing: PTFE. Fasteners: Type 316 stainless steel.

3. Valves shall be Nibco 590, Marwin CV 3000, or equal. 2.6 CORPORATION STOPS: TAG TYPE CS

A. Corporation Stops 3/4-inch through 2-inch shall be ball valve type, meeting AWWA Standard C800-01, Sec. 4.2.3 (High Pressure), withstanding working pressures up to 300 psi. Body, ball, operating stem, T-head, and service line connector shall be manufactured from red brass and conform to ASTM B 62 and/or ASTM B 584, UNS No. C83600. Ball shall be fluorocarbon coated and shall float on two EPDM seats and be watertight in both directions. Operating stem and nut shall be one piece, held in place by a mating machined flange on stem and in body. Operating stem shall have an EPDM O-ring to provide a watertight seal against the body.

B. Inlet threads shall be AWWA Taper, except where used with service clamps, where threads shall be IPS threads. Thread types and diameters shall conform to AWWA C800. Inlet threads will be integral to body. Waterway diameter shall be approximately equivalent to nominal size of stop, and shall accommodate maximum cutter size established by AWWA C800. Outlet shall be a compression connection meeting AWWA C800 Sec. 4.4.9.

C. Corporation Stops shall be FB Style Ballcorp, as manufactured by The Ford Meter Box Company, Inc., Wabash, Indiana, or equal. Where corporation stops are used with plastic pipe, a brass companion flange shall be provided on outlet of each corporation stop.

2.7 AIR RELEASE, VACUUM RELIEF AND COMBINATION VALVES: TAG TYPE NOTED BELOW

A. Pipeline air and vacuum valves shall be supplied with shutoff gate or ball valves with operator handle or lever removed. Valves shall be properly vented and piped to drain.

B. Valve pressure rating shall be at least equal to attached pipe's rating.

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Valves 15100 - 13


C. Valves for sewage and stormwater service shall have connections for draining and flushing with isolation ball valves for connection size up to 3 inch, and solid wedge gate valves for size 4 inch and larger.

D. Air Release Valves: Tag Type ARV.

1. Small orifice assembly air release valves shall automatically release air accumulations from pipe while under positive pressure. When valve body fills with air, float mechanism shall fall to open small orifice and exhaust air to atmosphere. When air has been exhausted, float mechanism shall be buoyed up and shall tightly close small orifice. Small orifice assembly shall be furnished with Type 304 stainless steel body and cover, and shall use Type 316 stainless steel hardware. Float mechanism shall be constructed of polypropylene or Type 316 stainless steel. Wetted components shall be polypropylene, Buna-N or Type 316 stainless steel. A resilient, Buna-N seat shall provide drop-tight closure.

2. Separate air release valves shall be Vent-O-Mat Model RBXb, equal as manufactured by APCO; Val-Matic; GA; Crispin or equal of the special type for use with non-clean water.

E. Vacuum Relief Valves: Tag Type VRV.

1. Large orifice assembly vacuum valves shall automatically allow air to enter pipeline when pressure falls below atmospheric pressure. Vacuum relief valves shall not be configured to release air.

2. Vacuum relief valves shall be constructed as specified in subparagraph F below, except providing vacuum relief only, as manufactured by Vent-O-Mat.

F. Combination Air and Vacuum Relief Valves: Tag Type CAV.

1. Valves shall be designed to release large amounts of air during pipeline filling, release small amounts of air accumulated during pipeline operation, and allow large volume of air during pipeline drainage or pipe break. Combination double orifice air/vacuum valve for general service in sizes 1 to 6 inches housed in a tubular stainless steel body with epoxy powder coated cast iron or steel ends secured by means of stainless steel tie rods. Valve shall have an intake orifice area equal to nominal size of valve.

2. Air release/vacuum valves shall be compact single cylindrical chamber design with multiple solid cylindrical HDPE control floats. Discharge of pressurized air shall be controlled by seating and unseating of a small orifice nozzle on a natural rubber seal affixed into control float. Nozzle shall have a flat seating land surrounding orifice so that damage to rubber seal is prevented. Venting of large quantities of air during pipeline filling shall be accomplished through large orifice at top of valve. Large orifice sealing shall be affected by flat face of control float seating against an "O" ring housed in a dovetail groove circumferentially surrounding orifice. Valve shall feature integral 'Anti-Shock' Orifice mechanism in op float which shall operate automatically to limit transient pressure rise or shock induced by closure to twice valves rated working pressure. Vacuum relief shall be accomplished through large

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Valves 15100 - 14


orifice when control floats fall due to negative pressure in pipeline. Valve design shall incorporate an over pressure safety feature that will fail without an explosive effect, such as is normally the case when highly compressed air is released suddenly. Feature shall consist of easily replaceable gaskets.

3. Valves shall be rated for 230 psi service. Materials of construction shall be as

follows: barrel- Type 304L stainless steel; top and bottom flanges- fusion bonded epoxy steel; upper/lower floats and anti-shock orifice- UHMW PE; small orifice nozzle seat and O-rings- Buna-N; nozzle, baffle plate, tie rods, studs, nuts, washers- Type 304 stainless steel. End Connections shall be NPT up to 2 inch, 125 lb flange 3 to 6 inch.

4. Valves shall be as manufactured by Vent-O-Mat, Model RBX 2521 or 1631.

2.8 SURFACE PREPARATION AND SHOP COATINGS

A. Notwithstanding any of these specified requirements, coatings and lubricants in contact with potable water shall be certified as acceptable for use with that fluid.

B. If not specified herein, coatings shall comply with the requirements of Section 09901and 09902. In case of a conflict, requirements of this Section govern.

C. If manufacturer's requirement is not to require finished coating on interior surfaces, then manufacturer shall so state and no interior finish coating will be required, if acceptable to Engineer.

D. Exterior surface of various parts of valves, operators, floor-stands and miscellaneous piping shall be thoroughly cleaned of all scale, dirt, grease or other foreign matter and thereafter one shop coat of an approved rust-inhibitive primer such as Inertol Primer No. 621 shall be applied in accordance with instructions of paint manufacturer or other primer compatible with finish coat provided.

E. Unless otherwise noted, interior ferrous surfaces of valves shall be given a shop finish of an asphalt varnish conforming to AWWA C509, (except mounting faces/surfaces) or epoxy conforming to AWWA C550 with a minimum thickness of 6 mils.

F. Ferrous surfaces obviously not to be painted shall be given a shop coat of grease or other suitable rust-resistant coating. Mounting surfaces shall be especially coated with a rust preventative.

G. Special care shall be taken to protect uncoated items and plastic items, especially from environmental damage.

2.9 FACTORY INSPECTION AND TESTING

A. Factory inspection, testing and correction of deficiencies shall be done in accordance with the referenced standards and as noted herein.

B. See Division 1 for additional requirements. Also refer to Part 1, especially for required submission of test data to Engineer.

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Valves 15100 - 15


C. In addition to tests required by referenced standards, the following shall also be factory tested:

1. All types of air and vacuum valves.

PART 3 EXECUTION

3.1 INSTALLATION - GENERAL

A. Valves and appurtenances shall be installed per manufacturer's instructions in locations shown, true to alignment and rigidly supported. Damage to above items shall be repaired to satisfaction of Engineer before they are installed.

B. Install brackets, extension rods, guides, various types of operators and appurtenances as shown on Drawings, or otherwise required. Before setting these items, check Drawings and figures which have a direct bearing on their location. Contractor shall be responsible for proper location of valves and appurtenances during construction of the work.

C. Materials shall be carefully inspected for defects in construction and materials. Debris and foreign material shall be cleaned out of openings, etc. Valve flange covers shall remain in place until connected piping is in place. Operating mechanisms shall be operated to check their proper functioning and nuts and bolts checked for tightness. Valves and other equipment which do not operate easily, or are otherwise defective, shall be repaired or replaced at no additional cost to Owner.

D. Where installation is covered by a referenced standard, installation shall be in accordance with that standard, except as herein modified, and Contractor shall certify such. Also note additional requirements in other parts of this Section.

E. Unless otherwise noted, joints for valves and appurtenances shall be made up utilizing same procedures as specified under applicable type connecting pipe joint and valves and other items shall be installed in proper position as recommended by manufacturer. Contractor shall be responsible for verifying manufacturers' torqueing requirements for all valves.

3.2 INSTALLATION OF MANUAL OPERATIONAL DEVICES

A. Unless otherwise noted, operational devices shall be installed with units of factory, as shown on Drawings or as acceptable to Engineer to allow accessibility to operate and maintain item and to prevent interference with other piping, valves, and appurtenances.

B. For manually operated valves 3-in in diameter and smaller, valve operators and

indicators shall be rotated to display toward normal operation locations.

C. For manually operated plug valves, valve operators and indicators shall be positioned for access and minimize height above basin floor/sidewall.

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3.3 INSPECTION, TESTING AND CORRECTION OF DEFICIENCIES

A. See also Division 1. Take care not to over pressure valves or appurtenances during pipe testing. If unit proves to be defective, it shall be replaced or repaired to satisfaction of Engineer.

B. Functional Test: Prior to system startup, items shall be inspected for proper alignment, quiet operation, proper connection and satisfactory performance. After installation, manual valves shall be opened and closed in presence of Engineer to show valve operates smoothly from full open to full close and without leakage. Air and vacuum valves shall be operated in presence of Engineer to show they perform their specified function at some time prior to placing piping system in operation and as agreed during construction coordination meetings.

C. Various pipe lines in which valves and appurtenances are to be installed are specified to be field tested. During these tests, any defective valve or appurtenance shall be adjusted, removed, and replaced, or otherwise made acceptable to Engineer.

D. Various regulating valves, strainers, or other appurtenances shall be tested to demonstrate their conformance with specified operational capabilities and deficiencies shall be corrected or device replaced or otherwise made acceptable to Engineer.

3.4 CLEANING

A. Items including valve interiors shall be inspected before line closure, for presence of debris. At option of Engineer, internal inspection of valve and appurtenances may be required any time that likelihood of debris is a possibility. Pipes and valves shall be cleaned prior to installation, testing disinfection and final acceptance.

3.5 DISINFECTION

A. Disinfection of valves and appurtenances on potable water lines and where otherwise noted, shall be as noted in Paragraph 1.02B above.

END OF SECTION

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Piping Specialties 15120- 1


SECTION 15120 PIPING

SPECIALTIES

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and install complete test, and make ready for operation all piping specialties required by the work of this Contract. Specific piping materials, systems and related installation and testing requirements shall be coordinated with the related sections in Divisions 2 and 15. The items shall include the following:

1. Unions.

2. Flanged Joints.

3. Dielectric Connectors.

4. Plugs and Caps.

5. Miscellaneous Adaptors.

6. Vents and Drains.

7. Service Clamps.

8. Quick Connect Couplings.

9. Mechanical Sleeve Seals.

10. Flexible Connectors:

a. Sleeve Couplings.

b. Split or Grooved Couplings.

c. Flange Adapters/Dismantling Joints.

11. Expansion Joints:

a. Expansion Couplings.

b. Single- and Multiple-Arch Type.

c. Bellows Style.

12. Harnessing and Restraints.

13. Pipe Cleaning Equipment.

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14. Appurtenances and Miscellaneous Items.

15. Color Coding and Labeling.

1.02

RELATED WORK

A. Pipeline color coding and labeling is included in Section 09902.

B. Piping materials and systems are included in other Sections of Division 15.

C. Specialties and apparatus furnished with equipment and systems are included in

individual Sections in Division11.

D. Valves are included in Section 15100.

E. Pipe supports are included in Section 15140.

1.03

SUBMITTALS

A. Submit, in accordance with Section 01300, general submittals for piping, piping

systems and pipeline appurtenances are listed below. It is not intended that all submittals listed below be provided for all piping materials and systems. Refer to individual System or Piping Sections for specific submittals.

B. Shop Drawings and Product Data:

1. Piping layouts with specialties.

2. Location of pipe hangers and supports.

3. Location and type of backup block or device to prevent joint separation.

4. Large scale details of wall penetrations and fabricated fittings.

5. Catalog cuts of specialties, joints, couplings, harnesses, expansion joints, gaskets,

fasteners and other accessories.

6. Catalog cuts of all pipeline appurtenances specified herein.

7. Brochures and technical data on coatings and linings and proposed method for

application and repair.

C. Samples.

D. Design Data.

E. Test Reports:

1. Minimum of four copies of certified shop tests showing compliance with appropriate

standard.

2. Minimum of four copies of all field test reports, signed by Contractor.

Bid Set April 2017



F. Certificates:

1. Copies of certification for all welders performing work in accordance with ANSI B31.1.

G. Manufacturer’s Installation (or application) instructions.

H. Statement of Qualifications.

I. Manufacturers Field Report.

J. Project Record Document.

K. Operation and Maintenance Data in accordance with Section 01730.

L. Warranties.




2. ASTM A126 - Standard Specification for Gray Iron Casting for Valves, Flanges and Pipe Fittings.

3. ASTM A183 - Standard Specification for Carbon Steel Track Bolts and Nuts.

4. ASTM A278 - Standard Specification for Gray Iron Castings for Pressure-Containing Parts for Temperatures up to 650 Degrees F.

5. ASTM A307 - Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength.

6. ASTM A325 - Standard Specification for Strength Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength.


8. ASTM A575 - Standard Specification for Steel Bars, Carbon, Merchant Quality, M-Grades.

9. ASTM B62 - Standard Specification for Composition Bronze or Ounce Metal

Castings.

10. ASTM B88 - Standard Specification for Seamless Copper Water Tube.

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1. ANSI A13.1 - Scheme for the Identification of Piping Systems.

2. ANSI B1.1 - Unified Inch Screw Threads (UN and UNR Thread Form).

3. ANSI B18.2 - Square and Hex Bolts and Screws Inch Series Including Hex Cap Screws and Lag Screws.

4. ANSI B31 - Code for Pressure Piping.

5. ANSI B31.1 - Power Piping.

C. American Society of Mechanical Engineers (ASME):

1. ASME B2.1 - Specifications, Dimensions, Gauging for Taper and Straight Pipe Threads (except dry seals).

2. ASME B16.1 - Cast Iron Pipe Flanges and Flanged Fittings.

3. ASME B16.5 - Pipe Flanges and Flange Fittings.

D. American Welding Society (AWS):

1. AWS B3.0 - Welding Procedure and Performance Qualifications.

E. American Water Works Association (AWWA):

1. AWWA C110 - Ductile-Iron and Gray-Iron Fittings, 3-in Through 48-in (75mm Through 1200mm), for Water and Other Liquids.


3. AWWA C219 - Bolted Sleeve-Type Couplings for Plain-End Pipe.


5. AWWA Manual M11 - Steel Pipe - A Guide for Design and Installation.

F. Underwriters Laboratories (UL).

G. Factory Mutual (FM).



A. Materials shall be new and unused.

B. Install piping to meet requirements of local codes.

Bid Set April 2017



C. Provide manufacturer's certification that materials meet or exceed minimum requirements as specified.

D. Coordinate dimensions and drilling of flanges with flanges for valves, pumps and other

equipment to be installed in piping systems. Bolt holes in flanges to straddle vertical centerline.

E. Reject materials contaminated with gasoline, lubricating oil, liquid or gaseous fuel,

aromatic compounds, paint solvent, paint thinner and acid solder.

F. Pipe-joint compound, for pipe carrying flammable or toxic gas, must bear approval of UL or FM.

G. Unless otherwise specified, pressures referred to in all Piping Sections are expressed in

pounds per square inch, gauge above atmospheric pressure, psig and all temperature are expressed in degrees Fahrenheit (F).

H. A factory trained representative (or direct employee) of the coupling manufacturer shall

provide on-site training for contractor’s field personnel in the use of grooving tools, application of groove, and product installation. The representative shall periodically visit the job site and review installation to ensure best practices in grooved joint installation are being followed. Contractor shall remove and replace any improperly installed products.


A. During loading, transportation and unloading, take care to prevent damage to pipes and coating. Carefully load and unload each pipe under control at all times. Place skids or blocks under each pipe in the shop and securely wedge pipe during transportation to ensure no injury to pipe and lining. Cover or cap all pipe ends while pipe is in storage, until it is made a part of the work.

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

A. Specific piping materials and appurtenances are specified in the respective Piping or System Sections. The use of a manufacturer's name and/or model number is for the purpose of establishing the standard of quality and general configuration desired.

B. Equipment shall be of the size shown on the Drawings or as noted and as far as possible equipment of the same type shall be identical and from one manufacturer.

C. Equipment shall have the name of the maker, nominal size, flow directional arrows (if

applicable), working pressure for which they are designed and standard referenced specifications cast in raised letters or indelibly marked upon some appropriate part of the body.

D. Unless otherwise noted, items shall have a minimum working pressure of 150 psi or be of the same working pressure as the pipe they connect to, whichever is higher and suitable for the pressures noted where they are installed.

Bid Set April 2017



2.2 UNIONS

A. Unions shall be brass or bronze unions for joining nonferrous pipe; malleable brass or bronze-seated iron or steel unions for joining ferrous pipe; PVC unions for joining PVC pipe; CPVC unions for joining CPVC pipe.

2.3 FLANGED JOINTS

A. Flanged Joints. Bolt and nuts, Grade B, ASTM A307, bolt number and size same as flange standard; studs - same quality as machine bolts; 1/16-in thick rubber gaskets with cloth insertions; rust-resistant coatings.

2.4 DIELECTRIC CONNECTORS

A. Dielectric pipe fittings/insulators and unions shall be used to prevent galvanic action wherever valves or piping of dissimilar metals connect. This shall be particularly the case for copper, brass and bronze piping connecting to cast iron or steel piping systems.

B. Dielectric unions shall be used for 2-in and smaller connections. Steel union nuts shall

meet ASTM A575 requirements. The steel or ductile iron connection end shall have a steel body and shall have accurately machined taper tapped pipe threads in accordance with ASME B2.1. The copper connection end shall be a copper solder joint that meets requirements of ASTM B88. Dielectric unions shall be rated for at least 250 psi at 210 degrees F.

C. Dielectric flange unions shall be used for connections 2-1/2-in and larger. Cast iron

flanges shall meet ASTM A126; the copper solder end shall meet ASTM B62 and the pipe thread shall meet ASME B2.1. Dielectric flange unions shall be rated for at least 175 psi at 210 degrees F.

D. Dielectric unions and flange unions shall be as manufactured by Epco Inc., Cleveland, OH

or equal.

E. Flange insulating kits shall be as acceptable to the Engineer, as manufactured by PSI or equal.

2.5 PLUGS AND CAPS

A. Provide standard plug or cap as required for testing; plugs, caps suitable for permanent service.

B. Plug or cap or otherwise cover all piping work in progress.

2.6 MISCELLANEOUS ADAPTORS

A. Between different types of pipe and/or fittings special adapters may be required to provide proper connection. Some of these may be indicated on the Drawings or specified with individual types of pipe or equipment. However, it is the Contractor's responsibility to ensure proper connection between various types of pipe, to structures

Bid Set April 2017



and between pipe and valves, gates, fittings and other appurtenances. Provide all adapters as required, whether specifically noted or not.

B. As required, these adapters shall be suitable for direct bury, with proper dielectric

insulation and as a minimum, if metallic (not stainless steel or galvanized), with two coats of Coal Tar Epoxy.

2.7 VENTS AND DRAINS

A. 1/2-in vents shall be provided at the high point in each system. Vent connections may be tapped, provided the tap will accept three full threads on the bronze nipple.

B. 2-in drains shall be provided to permit drainage of each system located on the invert of the

blind flange; provide hose-end valve.

2.8 SERVICE CLAMPS

A. Service clamps for outlet sizes 4-inch through 12-inch where the outlet size is not greater than half the size of the main pipe shall have ductile iron bodies and a neoprene circular cross section O-ring gasket confined within the body. Outlet shall be AWWA C110 flange or AWWA C111 mechanical joint as required for the application. Straps shall be alloy steel, minimum 1/4-inch by 1-1/2-inch in cross section and fabricated with 3/4-in threaded ends. Service clamps shall be Fig. A-10920 or A-30920 by American Cast Iron Pipe Company or equal.

B. Where weld-on outlets shown on the Drawings, service clamps shall not be furnished as an alternate.

2.9 QUICK CONNECT COUPLINGS

A. Couplings shall be of the cam and groove type consisting of a male adapter conforming to MIL-C-27487. Male adapters shall be designed to receive a female coupler without requiring threading, bolting, or tools. Connections shall remain tight and leak-proof under pressures up to 100 psig. Each adapter shall be furnished with a dust cap complete with a 18-in long security chain of corrosion resistant material. Couplings shall be by Civacon, a Division of Dover Corporation; Ever-tite or equal. Units shall be "drip proof", providing totally dry connections and dis-connections.

B. Adapters shall be furnished in accordance with the Drawings, or as required by the

installation.

2.10 MECHANICAL SLEEVE SEALS

A. Mechanical sleeve seals shall be used to secure and seal the annular space around all new sleeved and core-drilled wall penetrations if shown on the Drawings.

B. A single seal shall be provided for all sleeve and cores in walls up to 14-in thick; dual

sleeves shall be provided in larger walls.

Bid Set April 2017



C. Galvanized steel wall sleeves and concrete core diameter shall be sized sufficiently larger to accommodate the modular elements, per the manufacturer's recommendations.

D. Bolts and hardware shall be carbon steel, zinc-plated. Pressure plates shall be

corrosion-resistant acetal resin.

E. Mechanical sleeve seals shall consist of modular bolted, synthetic rubber sealing elements, Link Seal by Thunderline Corp. or equal.

2.11 FLEXIBLE CONNECTORS

A. Sleeve Couplings:

1. Provide plain end type ends to be joined by sleeve couplings as stipulated in AWWA C219.

a. Join welds on ends by couplings without pipe stops. Grind flush to permit

slipping coupling in at least one direction to clear pipe joint.

b. Outside diameter and out-of-round tolerances shall be within limits specified by coupling manufacturer.

c. Provide lugs in accordance with ASTM A36.

d. Provide hardened steel washers in accordance with ASTM A325.

e. Plastic plugs shall be fitted in coupling to protect bolt holes.

f. Nuts and bolts:

1) Provide bolts and bolt-studs in accordance with ASTM A307 and ANSI B1.1 with hexagonal or square heads, coarse thread fit, threaded full length with ends chamfered or rounded.

2) Project ends 1/4-in beyond surface of nuts. 3) Hexagonal nuts with dimensions in accordance with ANSI B18.2 and

coarse threads in accordance with ANSI B1.1.

2. Middle ring of each mechanical coupling shall have a thickness at least equal to that specified for size of pipe on which coupling is to be used and shall not be less than 10 inches long for pipe 30 inches and larger and not less than 7-inches long for pipe under 30-inches in diameter.

a. Omit pipe stop from inner surface of middle rings of couplings whenever

necessary to permit removal of valves, flowmeters and other installed equipment.

b. Provide pipe stops in other couplings.

3. Clean and shop prime with manufacturer's standard rust inhibitive primer.

4. Provide gaskets of a composition suitable for exposure to the fluid service.

Bid Set April 2017



5. Where shown on the Drawings, anchor sleeve-coupled joints with harness bolts. Weld harness lugs to steel pipe.

a. Joint harness bolts shall be of sufficient length, with harness lugs placed so

that coupling can be slipped at least in one direction to clear joint. Provide harnesses of sufficient number and strength to withstand test pressure as recommended in AWWA M-11.

b. Each harness shall have a minimum of two 5/8-in diameter bolts.

6. Unless otherwise specified with the individual type of pipe, sleeve couplings

(mechanical couplings) shall be ITT (formerly Smith Blair) Style 411; Dresser Style 38, similar models by Baker or equal, with the pipe stop removed.

7. Similar insulation type couplings shall be provided at the face of buildings, between different type metals or where otherwise noted.

8. In addition to those locations noted on the Drawings, sleeve couplings shall be

provided on all piping where it connects with a structure or buried directly under a structure at the structure's expansion joints. Special treatment will be required where pipe is encased in concrete, utilizing minimum 3-in thick styrofoam placed perpendicular to the horizontal centerline of the coupling.

B. Split or Grooved Couplings:

1. Split couplings shall be cast in two or more parts. When secured together with ASTM A449 and ASTM A183 bolts and nuts, couplings shall engage grooved or shouldered pipe ends and encase an elastomeric gasket to create a pipe seal. Gasket material shall be as recommended by the manufacturer for the service required.

2. Split couplings shall be as manufactured by Victaulic Company of America or

equal. Numbers below refer to Victaulic Co. items, for reference only.

3. Unless otherwise specified with the individual type of pipe:

a. Flexible split ring couplings shall be: 1) Grooved Ends: Style 77 (for steel/stainless steel) or Style 31 (for grooved

ductile iron). a) For steel pipe sizes through 12 inches: Victaulic Installation-Ready

couplings, Style 177(flexible) for direct stab installation without field disassembly.

2) Shouldered Ends: Victaulic Style 44 or Fluid Master. 3) Fixed Ends: Victaulic Depend-O-Lok, F x F (fixed by fixed).

b. Rigid split ring couplings shall be:

1) Grooved Ends: Rigid groove with Style 31 couplings on ductile iron 36-in and smaller diameter with sufficient wall thickness per AWWA C606, or manufacturer's recommendation, or standard groove with Style 07 Zero- Flex coupling on manufactured steel pipe of IPS size.

Bid Set April 2017



a) For direct connection of ductile iron pipe to steel pipe of IPS sizes – Victaulic Style 307 transition coupling with offsetting, angle-pattern, bolt pads.

b) For steel pipe sizes through 12”, Victaulic Installation-Ready couplings, Style 107H/107N (rigid) for direct stab installation without field disassembly.

2) Shouldered Ends: Style 44 coupling on ductile iron over 36-in diameter or without sufficient wall thickness per AWWA C606 or on manufactured steel pipe or thin wall stainless steel pipe. Field welding of shoulders of ductile iron pipe is specifically prohibited.

4. Ductile iron pipe for use with split-type coupling joints shall have radius grooved ends conforming to AWWA C606. Pipe shall have grooved ends to provide either a rigid joint or flexible joint as shown on the Drawings and as specified herein. Flexible joint grooving shall permit expansion and contraction, and angular deflection. Rigid joint grooving shall allow no angular or linear movement. Minimum pipe wall thickness for grooved pipe shall be the following class:

Size Class 4 thru 16 53 18 54 20 55 24 56

5. Grooved couplings for steel and stainless steel piping shall have roll grooving,

machine-grooving, or ring collars fully welded to the pipe or fitting.

6. Rigid split couplings may be substituted for flanges as noted on the Drawings and in the individual pipe requirements.

7. Certain minimum thickness of pipe walls is required by AWWA C606 and coupling manufacturers for use of various type split couplings with certain pipes. Utilize at least those minimum wall thicknesses required (unless a greater thickness is specified or required in the individual pipe specifications) with split couplings.

8. If minimum thicknesses are not utilized with grooving, then a shouldered end treatment with couplings as noted shall be utilized.

9. Gasket shall be manufactured by the coupling manufacturer and verified as suitable for the intended service.

C. Flanged Adaptors/Dismantling Joints:

1. Flanged adaptor connections for grooved or shouldered end pipe compatible with split couplings at fittings, valves and equipment shall be VIC-Flange Style 341 as manufactured by the Victaulic Company of America, or equal product as manufactured by Gustin-Bacon.

2. Flanged adaptor connections for plain end pipe at fittings, valves and equipment shall be Dresser Style 127 or 128, similar models by ITT (formerly Smith-Blair); Baker or equal.

Bid Set April 2017



3. Where shown or noted on the Drawings, restrained flanged adapters shall be furnished as dismantling joints as manufactured by Viking-Johnson, Romac Industries Inc. Style DJ400 or approved equal. Joint restraint rods shall be provided for pressure piping systems.

4. Dismantling joints for the WWF pump station discharge piping shall be AWWA C207 Class D steel ring flange compatible with ANSI Class 150 bolt circle, pipe shall be ASTM A36 steel plate. Gasket material shall be compatible with stormwater and intermittent contact with jet fuel. Tie rods (restraint rods) number and size as recommended by dismantling joint manufacturer.

5. All flanged adaptors and dismantling joints shall have working pressure rating matching the connecting piping and system as required by Engineer, be fusion bonded epoxy coated, and with stainless steel hardware and restraint systems.

2.12 EXPANSION JOINTS

A. Expansion Couplings:

1. Bolted split sleeve type couplings to allow for thermal expansion and contraction at the pipe joints shall consist of one piece housing, gasket assembly, bolts and nuts, and end rings to hold the coupling in the proper location.

2. Couplings shall be manufactured from ASTM A240 Type 304 or Type 316 stainless

steel material for use on stainless steel pipe. Couplings for use on carbon steel or ductile iron pipe shall be manufactured from ASTM A36 material. Gaskets shall be of a composition suitable for exposure to the fluid or air service.

3. Carbon steel couplings shall be coated in accordance with liquid epoxy coating per AWWA C210 or fusion bonded epoxy coating per AWWA C213. Manufacturers standard shop primer will not be accepted as a coating system. Stainless steel couplings shall be passivated after all welding is completed.

4. End rings of the same material as the coupling housing shall be welded to the plain end of the pipe ends that form the joint per the coupling manufacturer's recommendations to hold the coupling in the proper location.

5. Expansion joints shall be designed for the axial movements shown on the Drawings along with the maximum axial force required to compress the joint. The joints shall prevent axial, lateral and rotational movement and vibration from being transmitted to the piping and equipment and shall be suitable for 50 psig operating pressure unless otherwise indicated.

6. Expansion couplings for expansion joints for plain end pipe shall be Depend-O-Lok F x

E by Victaulic Depend-O-Lok, equal by Red Valve Company, or equal.

7. Expansion couplings for expansion joints for WWF discharge flanged pipe shall be Ex-Tend 200 flange by flange model by Ebaa Iron, Inc., or equal. Expansion couplings shall be equipped with restraining rods, nuts and accessories to facilitate flexibility for thermal expansion and contraction while maintaining restraint of pipe system in tension and compression due to other forces acting on system. Nuts

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shall be positioned to constrain extent of movement in both tension and compression to accommodate movement due to thermal expansion and contraction.

a. Provide ASTM A536 ductile iron body.

b. Shall be rated and tested at pressure of 250 psi.

c. Seals shall be EPDM and conform to requirements of ANSI/AWWA

C111/A21.11.

d. Flanged connections shall conform to requirements of ANSI/AWWA C110/A21.10 with addition of an o-ring gasket to ensure watertight seal.

e. Wetted parts shall be coated with NSF61 approved fusion bonded epoxy.

f. Exterior surfaces shall be coated with fusion bonded epoxy coordinated with

Division 9 coating specifications.

B. Single- and Multiple-Arch Type:

1. Expansion joints shall be of the rubber spool type, soft rubber filled with single-, double-, or triple-arch steel reinforced expansion joint, as indicated on the Drawings, suitable for 120 degrees F service, unless otherwise indicated.

2. Rubber used shall be suited for service with wastewater and/or wastewater sludge,

including three-ply abrasion resistant liner.

3. Provide galvanized retaining rings to mate with adjacent pipe flanges.

4. Expansion joints shall be designed for the axial movements along with the maximum axial force required to compress the joint. The joints shall prevent axial, lateral and rotational movement and vibration from being transmitted to the piping and equipment and shall be suitable for 50 psig operating pressure unless otherwise indicated.

5. Provide guides for each expansion joint.

C. Bellows Style:

1. Expansion joints shall be hydraulically formed (with dies on the outside only) and having only longitudinal seam welds. These seams shall have the same strength, physical properties and thickness as the parent metal without grinding. Expansion joints, bellow, and internal sleeves shall be made of Type 304 stainless steel with carbon steel flanges at each end. The entire inside length of the expansion joint shall be straight. Manufacturer to provide lifting lugs at each flange for ease in handling and removal sheet metal coverage for any expansion joint.

2. Expansion joints shall be designed to prevent rotational movement and vibration

from being transmitted to the piping and equipment and shall be suitable for 25 psig operation pressure unless otherwise specified.

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3. Expansion joints shall be suitable for continuous operating temperature range of 200 to 300 degrees F.

4. Hinged or Gimbal expansion joints shall be used at horizontal and vertical bends in

strict accordance with the standards of the EJMA, Inc.

5. Drilling and facing of flanges shall match or be suitable for use with equipment or companion flanges.

6. Guides shall be furnished with all bellows style expansion joints.

7. Manufacturer shall warrant this product to be suitable for the proposed conditions and shall furnish drawings for approval giving materials of construction, including gauge of corrugated element, maximum test pressure force to compress joint, bellows spring rate, shear force and end moment due to calculated traverse only. Manufacturer shall also furnish evidence of completing cycle life testing for the maximum diameter to be installed and shall indicate such assured cycle life test results on material submitted for approval.

2.13 HARNESSING AND RESTRAINT

A. Where harnessed couplings or adapters are noted, they shall conform to AWWA Manual M11 except as modified by the Drawings or this Section.

B. Unless otherwise noted, size and material for tie rods, clamps, plates and hex nuts shall

be as shown on the Drawings, or, if not shown on the Drawings, shall be as required in AWWA Manual M11. Manufactured restraining clamp assemblies shall be as manufactured by Stellar Corporation, Columbus, OH, or equal.

C. Restrained joints (such as welded, locking mechanical joints) shall be of the type

specified with the individual type of pipe. If not specified, restrained (locking) mechanical joint pipe shall be of the manufacturer's standard design utilizing a locking device (ring or ears) integrally cast with the pipe.

D. For up through 18-in diameter ductile iron pipe only, the following may be used as an alternative to other restraint system:

1. Optional mechanical joint restraints shall be incorporated in the design of a follower gland. The gland shall be manufactured of ductile iron conforming to ASTM A536. Dimensions of the gland shall be such that it can be used with the standardized mechanical joint bell and tee-head bolts as specified with the pipe.

2. Restraint mechanism shall consist of numerous individually activated gripping surfaces to maximize restraint capability. The gripping surfaces shall be wedges designed to spread the bearing surfaces on the pipe. Twist-off nuts, sized same as tee-head bolts, shall be used to ensure proper actuating of restraining devices. When the nut is sheared off, standard hex nut shall remain.

3. Mechanical joint restraint device for ductile iron pipe shall have a working pressure of

at least 250 psi with a minimum safety factor of 2:1.

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4. Mechanical joint restraint devices shall be of the type listed below or equal.

5. For Ductile Iron Pipe: EBAA Iron, Inc. Megalug 1100 series for up to 12 inches only.

E. Contractor shall be responsible for anchorage including restraint as noted elsewhere in

Division 15.

2.14 PIPE CLEANING EQUIPMENT

A. Pipe cleaning equipment shall consist of plastic projectiles ("pigs") and projectile launching vessels ("pig" launchers) suitable for use in cleaning 8-inch diameter pipelines.

B. "Pigs" shall be cylindrical, with a bullet shaped nose and concave base, covered with a

criss-cross pattern of hard rubber strips. Material of construction shall be resilient polyurethane foam with a density of 5 lbs/cu ft. Furnish four "pigs".

C. "Pig" launchers shall consist of adequately sized chambers to receive the "pigs". One end

of the chamber shall be provided with a reducer and flanged connection for attachment to the pipeline. The other end shall be provided with a hinged closure piece, using T-bolts for sealing and three 2-in diameter threaded connections fitted with isolation valves.

D. "Pig" launchers shall be of steel construction, suitable for 250 psi working pressure. The flange connection shall be flat face, matching ASME B16.1, 125 lb flanges.

E. Pipe cleaning equipment shall be as manufactured by Montauk Services, Inc. or equal.

F. A factory representative, who has complete knowledge of proper operation and maintenance shall be provided for one 8-hour day to instruct representatives of the Owner and Engineer on proper operation and maintenance, including startup and shutdown procedures, proper lubrication practices, if applicable, and troubleshooting of all equipment. If there are any difficulties with the training or in the operation of the equipment due to the manufacturer's design, fabrication or installation, additional startup and training services shall be provided at no additional cost to the Owner.

2.15 APPURTENANCES AND MISCELLANEOUS ITEMS

A. Gaskets, glands, bolts, nuts and other required hardware shall be provided for connection of piping and appurtenances. Hardware shall be of the size, type and number as required and recommended by the piping or appurtenance manufacturer and as specified herein.

B. Gaskets for flanges shall be full face and suitable for 200 degrees F operating

temperature, unless higher temperature required on individual systems and the fluids carried.

C. Plugs, caps and similar accessories shall be of the same material as the pipe and of the locking type, unless otherwise noted.

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D. Unions shall be of the same material as the pipe, except for dielectric connections.

E. Special protective tape shall be fabric reinforced petroleum tape by Denso Inc., Houston, TX or equal.

2.16 COLOR CODING AND LABELING

A. General:

1. Provide a complete color coding system consisting of preprinted labels and banding by Brady; Seton or equal. Field painting shall be specified in Section 09902.

2. Piping system identification shall comply with the requirements of ANSI A13.1.

3. Colors listed are general. Actual colors will be selected based on a comparison to the existing facility color codes, except as otherwise indicated; samples shall be furnished for all pipe paint colors; with chips from existing piping where new service lines are connecting.

4. Banding:

a. Unless special spacing is listed in schedule, apply banding to pipe at connections to equipment, valves, branch fittings, at wall, floor, or ceiling boundaries and at intervals not greater than 36-ft.

5. Labels and Directional Arrows:

a. Apply labels with directional arrows at connections to equipment, valves, branch fittings, at least one wall, floor, or ceiling boundary within a room and at intervals not greater than 36-ft.

b. At each label, arrows indicating direction of flow shall point away from label. If

flow may be in both directions, use double headed arrows.

c. Lettering shall bear the full pipe system name as scheduled.

d. Lettering height shall be as follows:

Outside Pipe Diameter Minimum Letter Height 3/4-in to 1-1/4-in 1/2-in 1-1/2-in to 2-in 3/4-in 2-1/2-in to 6-in 1-1/4-in 8-in to 10-in 2-1/2-in Over 10-in 3-1/2-in

e. Two labels minimum each room, crawl space or compartment, unless otherwise approved.

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PART 3 EXECUTION

3.1 GENERAL

A. Dirt, scale, weld splatter, water and other foreign matter shall be removed from the inside and outside of all pipe and sub-assemblies prior to installing.

B. Pipe joints and connections to equipment shall be made in such a manner as to produce a minimum of strain at the joint.

C. Test Connections:

1. Provide 1/2-inch female NPT test connection equipped with 1/2-inch brass plug on all pump suction and discharge lines. Where indicated on the Drawings, test connections should be equipped with bar stock valve and gauge. Provide test connections at all steam traps. The connection shall be located on the discharge side of the trap between the trap and the first valve. It shall consist of a 1/2-inch branch connection terminated with a gate valve.

D. Installation of Expansion Joints and Flexible Connectors:

1. Piping systems shall be aligned prior to installation of expansion fittings. Alignment shall be provided by fitting a rigid pipe spool in place of the expansion joint. Prior to testing of the piping system, the pipe spool shall be replaced with the specified expansion or flexible fitting.

2. In addition to the locations noted on the Drawings and in PART 2, expansion fittings and anchors shall be located and spaced as specified by the Expansion Joint Manufacturer's Association. The expansion joints/flexible connectors shall not be installed during times of temperature extreme or in a fully compressed or fully expanded condition.

E. Installation of Sleeve Couplings:

1. Unless otherwise required by the manufacturer's instructions, prior to installation of sleeve couplings, the pipe ends shall be cleaned thoroughly for a distance of at least 12-inches. Soapy water may be used as a gasket lubricant. A follower and gasket, in that order, shall be slipped over each pipe to a distance of about 6-in from the end, the middle ring shall be placed on the already installed pipe and shall be inserted into the middle ring flair and brought to proper position in relation to the pipe already installed. The gaskets and followers shall then be pressed evenly and firmly into the middle ring flares.

2. After the bolts have been inserted and all nuts have been made up fingertight,

diametrically opposite nuts shall be progressively and uniformly tightened all around the joint, preferably by use of a torque wrench of the appropriate size and torque for the bolts.

3. Correct torque as indicated by a torque wrench shall not exceed 75 ft-lb for 5/8-in bolts and 90 ft-lb for 3/4-in bolts.

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4. If a wrench other than a torque wrench is used, it should be no longer than 12-in so that when used by the average person the above torque values shall not be exceeded.

5. To prevent sleeve couplings from pulling apart under pressure, a suitable harnessing

or flange clamp assembly shall be provided and installed where shown on the Drawings, directed by the Engineer or required elsewhere under Division 15 concerning anchorage.

6. Note the additional locations required for sleeve couplings in PART 2. Also note Contractor's responsibility for locating, providing and installing restraints.

F. Installation of Split Couplings:

1. Prior to assembly of split couplings, grooves or shoulders of the pipe as well as other parts shall be thoroughly cleaned and free from indentations, projections and roll marks in the area from pipe end to and including groove. The ends of the pipes and outside of the gaskets shall be moderately coated with manufacturer's recommended lubricant, petroleum jelly, cup grease, soft soap, or graphite paste and the gasket shall be slipped over one pipe end. Lubricant shall be compatible with potable water application. After the other pipe has been brought to the correct position, the gasket shall be centered properly over the pipe ends with the lips against the pipes. The housing sections then shall be placed.

2. Ensure that the joints are fully extended after the rings are in place and prior to

tightening the bolts. After the bolts have been inserted, the nuts shall be tightened until the housing sections are firmly in contact, as required by the manufacturer, without excessive bolt tension or strain on the pipe.

G. Installation of Pipeline Appurtenances:

1. Pipeline appurtenances shall be installed as required and in accordance with the manufacturer's recommendations, as acceptable to the Engineer.

2. Gauges, meters and similar in-line items shall be isolated from testing pressures in excess of the rated pressure of the assembly.

3. Use Teflon tape on all screwed fittings.

H. Installation of Unions:

1. Use unions to allow dismantling of pipe, valves, and equipment.

I. Welding:

1. Welding shall be in accordance with ANSI B31 and AWS B3.0.

2. Install welding fittings on all welded lines. Make changes in direction and intersection of lines with welding fittings. Do not miter pipes to form elbows or notch straight runs to form tees, or any similar construction. Do not employ welder who

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has not been fully qualified in above specified procedure and so certified by approved welding bureau or similar locally recognized testing authority.

J. Installation of Flanged Joints:

1. Make flanged joints with bolts; bolt studs with nut on each end; or studs with nuts where one flange is tapped. Use number and size of bolts conforming to same ANSI Standard as flanges. Before flanges pieces are assembled, remove rust resistant coating from machined surfaces, clean gaskets and smooth all burrs and other defects. Make up flanged joints tight, care being taken to prevent undue strain upon valves or other pieces of equipment.

3.2 TESTING

A. Test all pipelines for water/gas tightness as specified in the Piping or System Sections. Furnish all labor, testing plugs or caps, pressure pumps, pipe connections, gauges and all other equipment required. Testing shall be performed in accordance with one or more of the testing procedures appended to this Section as specified in each Piping or System Section. All testing shall be performed in the presence of the Engineer.

B. Repair faulty joints or remove defective pipe and fittings and replace as approved by the Engineer. Retest.

3.3 DISINFECTION

A. After satisfactory testing, all protected water collection and distributed systems shall be thoroughly disinfected with a solution of not less than 50 ppm of available chlorine. The disinfecting solution shall be allowed to remain in the system for a period of three hours after which time all valves shall be opened and the system shall be flushed with clean water.

B. Water being flushed from structures or pipelines after disinfection with a chlorine residual of two mg/l or greater, shall be treated with a dechlorination solution, in a method approved by the Engineer, prior to discharge.

END OF SECTION

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Pipe Hangers and Supports 15140 - 1


SECTION 15140

PIPE HANGERS AND SUPPORTS

PART 1 GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals and install a complete system of pipe hangers, supports, concrete inserts and anchor bolts including all metallic hanging and supporting devices for supporting non-buried piping as shown on the Drawings and as specified herein.

B. The absence of pipe supports and details on the Drawings shall not relieve the Contractor of the responsibility for providing them. Pipe supports indicated on the Drawings are shown only to convey the intent of the design for a particular location and are not intended to represent a complete system.

1.2 RELATED WORK

A. Support design criteria is included in Section 01612.

B. Concrete is included in Division 3.

C. Miscellaneous metal is included in Section 05500.

D. Pipe and fittings are included in respective sections of Division15.

E. Valves are included in Section 15100.

1.3 SUBMITTALS

A. Submit, in accordance with Section 01300, complete sets of shop drawings of all items to be furnished under this Section. Submittals shall include complete layouts, schedules, location plans and complete total bill of materials for all pipe support systems.

B. Submittals shall include a representative catalog cut for each different type of pipe hanger or support indicating the materials of construction, important dimensions and range of pipe sizes for which that hanger is suitable. Where standard hangers and/or supports are not suitable, submit detailed drawings showing materials and details of construction for each type of special hanger and/or support. Provide detailed information on anti-seize compound.

C. Submittals shall include complete piping drawings as submitted for each piping submittal indicating type of hanger and/or support, location, magnitude of load transmitted to the structure and type of anchor, guide and other pipe supporting appurtenances including structural fasteners.

D. Types and locations of pipe hangers and/or supports shall also be shown on the piping layouts for each piping submittal as specified in the respective Division 15 pipe

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sections. Service conditions for each piping system, including service temperatures, and operating and test pressures, are tabulated in the piping sections.

E. Submit complete design data for pipe support systems to show conformance with this Section.

F. Support System Design

1. Engage the services of an independent registered professional engineer ordinarily engaged in the business of pipe support systems analysis, to analyze system piping and service conditions and to develop a detailed support system, specific to the piping material, pipe joints, valves and piping appurtenances proposed for use.

a. The proposed support system engineer shall have at least five years of

experience in the analysis and design of similar systems, including the use of commercial and custom pipe support and in the use of commercial pipe stress software programs. Provide a detailed resume, including references from projects within the past five years. The use of support systems engineer shall be subject to the approval of the Engineer.

2. The support system engineering services shall be provided by J. Blanco, Inc., Fairlawn, NJ, Waterford Associate Inc., East Providence, RI or DynaTech Engineering, Auburn, CA.

3. The proposed systems engineer shall attend a conference with the Engineer,

scheduled prior to any support systems design.

4. The support system design shall include:

a. Criteria by piping system.

b. Summary of Contractor-selected related components including joints, class, valves appurtenances, etc., and commercial supports and especially including pipe materials.

c. Dead weight and dynamic analysis, including system thermal effects and

pressure thrusts. Computer-based software system equivalent to ADLPIPE. 1) Each system shall be presented in an isometric graphic and shall show the

resolved and resultant force and moment systems, as well as all recommended hangers, supports, anchors, restraints and expansion/flexible joints.

d. Submit a draft report to the Engineer for approval.

1) After the work is installed, but before it is filled for start-up and testing, the support system design engineer shall inspect the work and shall certify its complete adequacy. Each system shall be inspected and certified in the same way.

2) Submit a report, including all field modifications and including all certificates.

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3) The report shall bear the stamp of a registered professional engineer and shall be subject to the approval of the Engineer.

e. All aspects of the analysis and design shall comply with the provisions of ANSI

B31.1 and the referenced standards.

f. Support arrangements shall be coordinated to eliminate interference with similar systems to be installed under Electrical; to account for structural expansion joints and to maintain access for both personnel and for the removal of equipment. Support systems shall not include the use of monorail or bridge crane support. Nor shall they rely on the horizontal structural struts.

g. Commercial hardware and custom supports shall comply with the

requirements of this Section.

h. Expansion joints shall comply with the provisions of Section 15120.

5. Prepare for and attend a post-analysis review and presentation, after the Engineer's review of the report. Revise per the comments and issue as FINAL REPORT.


A. Manufacturer's Standardization Society of the Valve and Fittings Industry (MSS):

1. MSS SP-58 - Pipe Hangers and Supports - Materials, Design and Manufacture.

2. MSS SP-69 - Pipe Hangers and Supports - Selection and Application.

B. ASTM International:


2. ASTM A307 - Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength.

C. American National Standards Institute (ANSI):

1. ANSI B31.1 - Power Piping.



A. All hangers, supports and appurtenances shall conform to the latest applicable requirements of ANSI B31.1, except as supplemented or modified by the requirements of this Section.

B. All hangers, supports and appurtenances shall be of approved standard design where possible and shall be adequate to maintain the supported load in proper position under

Bid Set April 2017



all operating conditions. The minimum working factor of safety for all supporting equipment, with the exception of springs, shall be five times the ultimate tensile strength of the material, assuming 10 feet of water-filled pipe being supported.

C. All pipe and appurtenances connected to equipment shall be supported in such a manner as to prevent any strain being imposed on the equipment. When manufacturers have indicated requirements that piping loads shall not be transmitted to their equipment, submit certification stating that such requirements have been complied with.


A. All supports and hangers shall be crated, delivered and uncrated so as to protect against any damage.

B. All parts shall be properly protected so that no damage or deterioration shall occur during a prolonged delay from the time of shipment until installation is completed.

C. Finished metal surfaces not galvanized, that are not of stainless steel construction, or that are not coated, shall be grease coated, to prevent rust and corrosion.

PART 2 PRODUCTS

2.1 GENERAL

A. All of the equipment specified herein is intended to support the various types of pipe and piping systems shown on the Drawings. It shall be the responsibility of the Contractor to develop final details and any details associated with special conditions not already covered to meet the system conditions (in particular system temperatures and pressures) specified in the respective Division 15 pipe sections.

B. All pipe and tubing shall be supported as required to prevent significant stresses in the pipe or tubing material, valves, fittings and other pipe appurtenances and to support and secure the pipe in the intended position and alignment. All supports shall be designed to adequately secure the pipe against excessive dislocation due to thermal expansion and contraction, seismic forces, internal flow forces and all probable external forces such as equipment, pipe and personnel contact. Structural steel members required to brace any piping from excessive dislocation shall conform to the applicable requirements of Section 05500 and shall be furnished and installed under this Section.

C. The Contractor may propose minor adjustments to the piping arrangements in order to simplify the supports, or in order to resolve minor conflicts in the work. Such an adjustment might involve minor change to a pipe centerline elevation so that a single trapeze support may be used.

D. Where flexible couplings are required at equipment, tanks, etc., the end opposite to the piece of equipment, tank, etc., shall be rigidly supported, to prevent transfer of force systems to the equipment. No fixed or restraining supports shall be installed between a flexible coupling and the piece of equipment.

Bid Set April 2017



E. All pipe and appurtenances connected to the equipment shall be supported in a manner to prevent any strain from being imposed on the equipment or piping system.

F. All rods, clamps, hangers, inserts, anchor bolts, brackets and components for interior pipe supports shall be furnished with galvanized finish, hot dipped or electro- galvanized coated, except where field welding is required, where cold-applied galvanizing may be used. Interior clamps on plastic pipe shall be plastic coated. Supports for copper pipe shall be copper plated or shall have a 1/16-inch plastic coating. All rods, clamps, hangers, inserts, brackets and components for exterior pipe, submerged pipe and pipe within outdoor structures shall be of galvanized finish as specified above. All anchor bolts shall be Type 316 stainless steel.

G. Supports shall be sufficiently close together such that the sag of the pipe is within limits that will permit drainage and avoid excessive bending stresses from concentrated loads between supports.

H. All uninsulated non-metallic piping such as PVC, CPVC, etc., shall be protected from local stress concentrations at each support point. Protection shall be provided by galvanized steel protection shields or other method as approved by the Engineer. Where pipes are bottom supported 180 degrees, arc shields shall be furnished. Where 360-degree arc support is required, such as U bolts, protection shields shall be provided for the entire pipe circumference. Protection shields shall have an 18-gauge minimum thickness, not be less than 12-in in length and be securely fastened to pipe with galvanized metal straps not less than 2-in wide.

I. All insulated pipe shall be furnished with a rigid foam insulating saddle at each pipe support location as specified under respective pipe insulation. Provide protection shields as specified in at each support location.

J. Where pipe hangers and supports come in contact with copper piping provide protection from galvanic corrosion by; wrapping pipe with 1/16-inch thick neoprene sheet material and galvanized protection shield; isolators similar to Elcen, Figure No. 228; or copper plated or PVC coated hangers and supports. All stainless- steel piping shall be isolated from all ferrous materials, including galvanized steel by use of neoprene sheet material and protection shields, similar to above methods.

K. Pipe supports shall be provided as follows:

1. Cast iron and ductile iron, steel and stainless steel piping shall be supported at a maximum support spacing of 6 feet with a minimum of one support per pipe section at the joints.

2. Insofar as is possible, floor supports shall be given preference. Typical concrete supports are required where shown on the process drawings. Base elbow and base tees shall be used where possible.

3. Support spacing for steel and stainless steel piping 2-inch and smaller diameter and copper tubing shall not exceed 5 feet.

Bid Set April 2017



4. For all stainless-steel piping, provide neoprene isolators between the pipe and support components.

5. Supports for multiple PVC plastic piping shall be continuous wherever possible. Individually supported PVC pipes shall be supported as recommended by the manufacturer except that support-spacing shall not exceed 3 feet. Multiple, suspended, horizontal plastic PVC pipe runs, where possible, shall be supported by ladder type cable trays such as the Electray Ladder by Husky-Burndy; the Globetray by the Metal Products, a Division of United States Gypsum, or equal. Ladder shall be of galvanized steel construction. Rung spacing shall be 12 inches. Tray width shall be approximately 6 inches for single runs and 12 inches for double runs. Ladder type cable trays shall be furnished complete with all hanger rods, rod couplings, concrete inserts, hanger clips, etc., required for a complete support system. Individual plastic pipes shall be secured to the rungs of the cable tray by strap clamps or fasteners similar to Globe, Model M-CAC; Husky-Burndy, Model SCR or equal. Spacing between clamps shall not exceed 9 feet. The cable trays shall provide continuous support along the length of the pipe. Individual clamps, hangers and supports in contact with plastic PVC pipe shall provide firm support but not so firm as to prevent longitudinal movement due to thermal expansion and contraction.

6. All vertical pipes shall be supported at each floor or at intervals of not more than 5 feet by approved pipe collars, clamps, brackets, or wall rests and at all points necessary to insure rigid construction. All vertical pipes passing through pipe sleeves shall be secured using a pipe collar.

7. Pipe supports shall not induce point loadings but shall distribute pipe loads evenly along the pipe circumference.

8. Supports shall be provided at changes in direction and elsewhere as shown in the Drawings or as specified herein. No piping shall be supported from other piping or from metal stairs, ladders and walkways, unless specifically directed or authorized by the Engineer.

9. Pipe supports shall be provided to minimize lateral forces through valves, both sides of split type couplings and sleeve type couplings and to minimize all pipe forces on pump housings. Pump housings shall not be utilized to support connecting pipes.

10. Effects of thermal expansion and contraction of the pipe shall be accounted for in the pipe support selection and installation.

L. Unless otherwise specified herein, pipe hangers and supports shall be standard catalogued components, conforming to the requirements of MSS-SP-58 and -69; and shall be as manufactured by Anvil International Co., Inc., Providence, RI; Carpenter & Patterson, Inc., Woburn, MA; F&S Central, Brooklyn NY; Elcen Metal Products Co., Franklin Park, IL and Unistrut Northeast, Cambridge, MA or equal. Reference to a specific figure number of a specific manufacturer is for the purpose of establishing a type and quality of product and shall not be considered as proprietary.

Bid Set April 2017



M. Required pipe supports for which the supports specified in this Section are not applicable shall be fabricated or constructed from standard structural steel shapes, concrete and anchor hardware similar to items previously specified herein and shall be subject to the approval of the Engineer.

N. Expansion anchors shall be equal to Kwik-Bolt as manufactured by the McCullock

Industries, Minneapolis, MN or Wej-it by Wej-it Expansion Products, Inc., Bloomfield, CO. The length of expansion bolts shall be sufficient to place the wedge portion of the bolt a minimum of 1-in behind the steel reinforcement.

O. All anchors subject to submergence in WWF PS and in stormwater detention basin shall be cast-in-place or adhesive anchors as shown on the Drawings.

P. Hanger rods shall be hot rolled steel, machine threaded and galvanized after fabrication. The strength of the rod shall be based on its root diameter. Hanger rods shall be attached to concrete structures using concrete inserts similar to F&S, Figures 180, 571 or 150; or continuous concrete inserts per F&S. Inserts shall be malleable iron, or steel with galvanized finish. Beam clamps, C clamps or welded beam attachments shall be used for attaching hanger rods to structural steel members. Where necessary and approved by the Engineer, expansion anchors shall be used for attaching to concrete structures.

2.2 SINGLE PIPE HANGERS

A. Single pipes shall be supported by hangers suspended by hanger rods from structural steel members, concrete ceilings, bottom of trapeze hangers and wall mounted steel angle brackets.

B. Except as otherwise specified herein, pipe hangers shall be steel, of the adjustable clevis type similar to Anvil International, Figure No. 65, 260 and 590 as required.

C. Where pipes are near walls, beams, columns, etc., and located an excessive distance from ceilings or underside of beams, welded steel wall brackets similar to Carpenter and Patterson, Figure No. 69-68, 84 or 139 shall be used for hanging pipe. Where single pipes rest on top of bracket pipe supports, attachments shall meet requirements as specified under multiple pipe hangers.

2.3 MULTIPLE PIPE HANGERS

A. Suspended multiple pipes, running parallel in the same horizontal plane, which are adjacent to each other shall be suspended by trapeze type hangers or wall brackets. Trapeze hangers shall consist of galvanized structural steel channel supported from galvanized threaded rod or attached to concrete walls, columns or structural steel support members as required to meet the intent of this Section. Channel shall be similar to F&S, Figure 710, rods, concrete inserts, "C" clamps, beam clamps, welded beam attachments and expansion shields shall be as specified in Paragraph 2.02 above.

B. Except as otherwise specified herein pipe anchors used for attaching pipe to trapeze or multiple pipe wall brackets shall be anchor or pipe chairs similar to F&S, Figures 158,

Bid Set April 2017



419, 160A, 160B as required. Material of construction shall be galvanized steel. Chair "U" bolts shall be tightened to allow freedom of movement for normal expansion and contraction except where pipe must be anchored to control direction of movement or act as a thrust anchor.

2.4 SINGLE AND MULTIPLE PIPE SUPPORTS

A. Single pipes located in a horizontal plane close to the floor shall be supported by one of the methods as shown on the Drawings and as specified herein.

B. Pipes 3-in in diameter and larger shall be supported by adjustable stanchions similar to F&S, Figure 427. Stanchions shall provide at least 4-in adjustment and be flange mounted to floor.

C. Pipes less than 3-in in diameter shall be held in position by supports fabricated from steel "C" channel, welded post base similar to Unistrut, Figure P2072A and pipe clamps similar to Unistrut, Figures P1109 thru P1126. Where required to assure adequate support, fabricate supports using two vertical members and post bases connected together by horizontal member of sufficient load capacity to support pipe. Wherever possible supports shall be fastened to nearby walls or other structural member to provide horizontal rigidity. More than one pipe may be supported from a common fabricated support.

D. Where shown on the Drawings, pipe shall be supported using concrete supports. Pipe shall be securely fastened to the supports using suitable metal straps as required and as approved.

2.5 WALL SUPPORTED PIPES

A. Single or multiple pipes located adjacent to walls, columns or other structural members, whenever deemed necessary, shall be supported using welded steel wall brackets similar to Carpenter and Patterson, Figure No. 69-78, 84, or 134; or "C" channel with steel brackets similar to Unistrut pipe clamps. All members shall be securely fastened to wall, column, etc., using double expansion shields or other method as approved by the Engineer. Additional wall bearing plates shall be provided where required.

B. Pipe shall be attached to supports using methods specified herein to meet the intent of this Section.

2.6 BASE ANCHOR SUPPORT

A. Where pipes change direction from horizontal to vertical via a bend, a welded or cast base bend support shall be installed at the bend to carry the load. The base bend shall be fastened to the floor, pipe stanchion, or concrete pedestal using expansion anchors or other method as approved by the Engineer.

B. Where shown on the Drawings, pipe bends shall be supported using concrete anchor posts. Pipes shall be securely fastened to the concrete supports with suitable metal bands as required and approved by the Engineer. A felt insert shall be used to isolate the piping from the poured concrete.

Bid Set April 2017



2.7 VERTICAL PIPE SUPPORTS

A. Where vertical pipes are not supported by a Unistrut system as specified in Paragraph 2.8 below, they shall be supported in one of the following methods.

1. For pipes 1/4-inch to 2 inches in diameter, an extension hanger ring shall be provided with an extension rod and hanger flange. The rod diameter shall be as recommended by the manufacturer for the type of pipe to be supported. The hanger ring shall be steel or PVC clad depending on the supported pipe. The hanger ring shall be equal to Carpenter & Paterson, Figure No. 81 or 81CT. The anchor flange shall be galvanized malleable iron similar to Carpenter and Patterson, Figure No. 85.

2. For pipes, equal to or greater than 2 inches in diameter extended pipe clamps similar to Carpenter and Patterson, Figure No. 267 may be used. The hanger shall be attached to concrete structures using double expansion shields, or to steel support members using welding lugs similar to Carpenter and Patterson, Figure No. 220.

3. Pipe riser clamps shall be used to support all vertical pipes extending through floor slabs. Riser clamps shall be steel similar to Carpenter and Patterson, Figure No. 126. Copper clad or PVC coated clamps shall be used on copper pipes. Insulation shall be removed from insulated pipes prior to installing riser clamps. Insulation shall not be damaged by clamp installation.

4. Unless otherwise specified, shown, or specifically approved by the Engineer, vertical runs exceeding 12-ft shall be supported by base elbows/tees, clamps, brackets, wall rests and pipe collars, all located as required to ensure a rigid installation.

2.8 SPECIAL SUPPORTS

A. Pipe supports shall be provided for closely spaced vertical piping systems required to provide a rigid installation. The interval of vertical support spacing shall be as specified, but in no case, shall vertical interval exceed 10 feet. The support system shall consist of a framework suitably anchored to floors, ceilings or roofs.

B. Vertical and horizontal supporting members shall be U shaped channels similar to Unistrut, Series P1000. Vertical piping shall be secured to the horizontal members by pipe clamps or pipe straps. All components shall be of steel.

C. For piping 3 inches and smaller, the framework shall be as manufactured by the Unistrut Corporation; Globe-Strut as manufactured by the Metal Products Division of U.S. Gypsum or equal. For piping larger than 3 inches, the support frame shall be fabricated from structural steel shapes and secured through the use of expansion anchors.

D. The assemblies shall be furnished complete with all nuts, bolts and fittings required for a complete assembly including end caps for all unistrut members.

Bid Set April 2017



E. The design of each individual framing system shall be the responsibility of the Contractor. Shop drawings, as specified above shall be submitted and shall show all details of the installation, including dimensions and types of supports. In all instances the completed frame shall be adequately braced to provide a complete rigid structure when all the piping has been attached.

F. Supports not otherwise described in this Section shall be fabricated or constructed from standard structural steel shapes in accordance with applicable provisions of Section 05500, or unistrut-type frame; have anchor hardware similar to items previously specified herein, shall meet the minimum requirements listed below and be subject to the approval of the Engineer.

1. Pipe support systems shall meet all requirements of this Section and all related Sections.

2. Complete design details of the pipe support system and system components shall be submitted for review and approval as specified in PART 1. No hanger or support shall be installed without the written approval of the Engineer.

3. The pipe support system shall not impose loads on the supporting structures in excess of the loads for which the supporting structure is designed.

2.9 SUPPORTS FOR GROOVED DUCTILE IRON PIPING

A. Grooved ductile iron piping systems proposed by the Contractor as substitute to the flanged ductile iron piping system shown on the Drawings and specified in Section 15072 shall be acceptable, in part, subject to the following hanger and support system revised requirements.

1. Take extreme caution in any and all field cut grooves, due to the criticality of the dimensions and location of the grooves. No field grooved piping shall be assembled without the inspection and verification of the groove by the Contractor and in the presence of the Engineer. All couplings connected to a field groove shall be spot-painted.

2. At each change in direction the piping shall be restrained against the axial direction of movement and against resultant pressure thrust, due to potential joint movement due to out-of-spec grooving.

B. If, in the course of testing or operation there is any pipe movement, it shall require the removal of the length of pipe.

2.10 SURFACE PREPARATION AND SHOP PRIME PAINTING

A. All surfaces shall be prepared and shop painted as part of the work of this Section. Surface preparation and shop painting shall be as specified in Section 09901.

Bid Set April 2017



PART 3 EXECUTION

3.1 INSTALLATION

A. Proceed with the installation of piping and supports only after any building structural work has been completed and new concrete has reached its 28-day compressive strength.

B. The installation of pipe support systems shall in no way interfere with the operation of the overhead bridge cranes, monorails, access hatches, etc.

C. The installed systems shall not interfere with maintenance and operational access to any equipment installed under this Section, or any other related Section.

D. All pipes horizontal and vertical, requiring rigid support shall be supported from the

building structure by approved methods. Supports shall be provided at changes in direction and elsewhere as shown in the Drawings or as specified herein. No piping shall be supported from metal stairs, ladders and walkways unless specifically directed or authorized by the Engineer.

E. All pipe supports shall be designed with liberal strength and stiffness to support the respective pipes under the maximum combination of peak loading conditions to include pipe weight, liquid weight, liquid movement and pressure forces, thermal expansion and contraction, vibrations and all probable externally applied forces. Prior to installation, all pipe supports shall be approved by the Engineer.

F. Pipe supports shall be provided to minimize lateral forces through valves, both sides of split type couplings and sleeve type couplings (within four pipe diameters) and to minimize all pipe forces on pump housings. Pump housings shall not be utilized to support connecting pipes.

G. Inserts for pipe hangers and supports shall be installed on forms before concrete is placed. Before setting these items, all Drawings and figures shall be checked which have a direct bearing on the pipe location. Responsibility for the proper location of pipe supports is included under this Section.

H. Continuous metal inserts shall be embedded flush with the concrete surface.

I. Apply anti-seize compound to all nuts and bolts. Supports installed without the approved compound shall be dismantled and correctly installed, at no additional cost to the Owner.

Bid Set April 2017



3.2 TESTING

A. All pipe support systems shall be tested for compliance with this Section. After installation, each pipe support system shall be tested in conjunction with the respective piping pressure tests. If any part of the pipe support system proves to be defective or inadequate, it shall be repaired or augmented under this Section to the satisfaction of the Engineer.

END OF SECTION

Bid Set April 2017

Electrical 16020-1


SECTION 16020

ELECTRICAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials and equipment required to install complete and make operational, electrical and process instrumentation systems as specified, as shown on the Drawings.

B. The work shall include furnishing and installing the following:

1. Electrical service from the Power Company.

2. Conduit, wire and field connections for all motors, motor controllers, control devices, control panels and electrical equipment furnished under other Divisions of these Specifications.

3. Conduit, wiring and terminations for all field-mounted instruments furnished and mounted under other Divisions of these Specifications, including process instrumentation primary elements, transmitters, local indicators and control panels. Lightning and surge protection equipment wiring at process instrumentation transmitters. Install vendor furnished cables specified under other Divisions of these Specifications.

4. Mount Reduce Voltage Soft Starters furnished under other sections of these specifications.

5. Furnish and install precast manholes, and handholes if required for utilities.

6. Furnish and install manhole and handhole frames and covers.

7. Grounding System.

8. Underground System.

C. Excavation, bedding material, forms, concrete and backfill for underground raceways; forms and concrete for electrical equipment furnished under Division 16. The work shall be in accordance with Divisions 2 and 3.

1.2 SUBMITTALS

A. Submit, in accordance with Section 01300, shop drawings for equipment, materials and other items furnished under Division 16.

B. Check shop drawings for accuracy and contract requirements prior to submittal. Shop drawings shall be stamped with the date checked and a statement indicating that the shop drawings conform to Specifications and Drawings. This statement shall also list all exceptions to the Specifications and Drawings. Shop drawings not so checked and noted shall be returned.

Bid Set April 2017

Electrical 16020-2


C. The Engineer's check shall be for conformance with the design concept of the project and compliance with the Specifications and Drawings. Errors and omissions on approved shop drawings shall not relieve the Contractor from the responsibility of providing materials and workmanship required by the Specifications and Drawings.

D. All dimensions shall be field verified at the job site and coordinated with the work of all

other trades.

E. In addition to manufacturer's equipment shop drawings, submit electrical installation working drawings containing the following:

1. All conduit layouts including exposed, concealed in floor slab, concealed in wall, and buried under the slab. Multiple plan view elevations shall be drawn to clearly show all conduits. Not less than 1/4-in = 1-ft-0-in scale. The layouts shall include locations of process equipment, motor control centers, transformers, panelboards, control panels and equipment, motors, switches, motor starters, large junction or pull boxes, instruments and any other electrical devices.

F. Material shall not be ordered or shipped until the shop drawings have been approved. No material shall be ordered or shop work started if shop drawings are marked "APPROVED AS NOTED - CONFIRM," "APPROVED AS NOTED - RESUBMIT" or "NOT APPROVED."

G. Operation and Maintenance Data

1. Submit operations and maintenance data for equipment furnished under this Division, in accordance with Section 01730. The manuals shall be prepared specifically for this installation and shall include catalog data sheets, drawings, equipment lists, descriptions, parts lists, etc., to instruct operating and maintenance personnel unfamiliar with such equipment.

1.3 CONTRACT PERFORMANCE REQUIREMENTS

A. Electric equipment, materials and installation shall comply with the latest edition of the National Electrical Code (NEC) and with the latest edition of the following codes and standards:

1. National Electrical Safety Code (NESC)

2. Occupational Safety and Health Administration (OSHA)

3. National Fire Protection Association (NFPA)

4. National Electrical Manufacturers Association (NEMA)

5. American National Standards Institute (ANSI)

6. Insulated Cable Engineers Association (ICEA)

7. Instrument Society of America (ISA)

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Electrical 16020-3


8. Underwriters Laboratories (UL)

9. Factory Mutual (FM)

10. National Electrical Testing Association (NETA)


1.4 PRIORITY OF THE CONTRACT DOCUMENTS

A. If, during the performance of the work, the Contractor finds a conflict, error or discrepancy between or among one or more of the Sections or between or among one or more Sections and the Drawings, furnish the higher performance requirements. The higher performance requirement shall be considered the equipment, material, device or installation method which represents the most stringent option, the highest quality or the largest quantity.

B. In all cases, figured dimensions shall govern over scaled dimensions. Work not dimensioned shall be scaled-off from the drawings.

C. Detailed Drawings shall govern over general drawings, larger scale Drawings take

precedence over smaller scale Drawings, Change Order Drawings shall govern over Contract Drawings and Contract Drawings shall govern over Shop Drawings.

D. If the issue of priority is due to a conflict or discrepancy between the provisions of the Contract Documents and any referenced standard, or code of any technical society, organization or association, the provisions of the Contract Documents will take precedence if they are more stringent or presumptively cause a higher level of performance. If there is any conflict or discrepancy between standard specifications, or codes of any technical society, organization or association, or between Laws and Regulations, the higher performance requirement shall be binding on the Contractor, unless otherwise directed by the Engineer.

E. In accordance with the intent of the Contract Documents, the Contractor accepts the fact that compliance with the priority order specified shall not justify an increase in Contract Price or an extension in Contract Time nor limit in any way, the Contractor's responsibility to comply with all Laws and Regulations at all times

1.5 ENCLOSURE TYPES

A. Unless otherwise specified electrical enclosures shall have the following ratings:

1. NEMA 1A gasketed for electrical room.

2. NEMA 3R for outdoor non-corrosive.

3. NEMA 4 for indoor pump room.

4. NEMA 4X for chemical room.

Bid Set April 2017

Electrical 16020-4


1.6 SERVICE AND METERING

A. The power company serving this project is Los Angeles Department of Water and Power (LADWP). Service will be obtained from a 1200A, 480y/277V, 3 Phase, 4 Wire switchboard.

B. The power company will be responsible for the following work:

1. Furnishing and installing the primary conductors.

2. Furnishing metering current transformers (CT's), meters and meter wiring.

C. Provide the following coordination, work and materials:

1. The Contractor is responsible for any work referred to as “customer” shown on the LADWP construction drawing. This work shall be included in the Contractor’s Bid Price.

Make all arrangements with the power company for obtaining electrical service and furnish all labor and material required for the electrical service.

1.7 CODES, INSPECTION AND FEES

A. Equipment, materials and installation shall comply with the requirements of the local authority having jurisdiction.

1.8 TESTS AND SETTINGS

A. Test systems and equipment furnished under Division 16 and repair or replace all defective work and equipment. Refer to the individual equipment sections for additional specific testing requirements.

B. Make adjustments to the systems and instruct the Owner's personnel in the proper operation of the systems.

C. In addition to the specific testing requirements listed in the individual sections, the following minimum tests and settings shall be performed.

1. Mechanical inspection, testing and settings of circuit breakers, disconnect switches, protection relays, motor starters, overload relays, control circuits and equipment for proper operation.

2. Check the full load current draw of each motor. Check ampere rating of thermal overloads for motors and submit a typed record to the Engineer of the same, including MCC cubicle location and driven load designation, motor service factor, horsepower, and Code letter. If incorrect thermal overloads are installed replace same with the correct size overload.

3. Check power and control power fuse ratings. Replace fuses if they are found to be of the incorrect size.

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Electrical 16020-5


4. Check settings of the motor circuit protectors. Adjust settings to lowest setting that will allow the motor to be started when under load conditions.

5. Check motor nameplates for correct phase and voltage. Check bearings for proper lubrication.

6. Check rotation of motors prior to testing the driven load. Disconnect the driven equipment if damage could occur due to wrong rotation. If the rotation is for the driven equipment is not correct, disconnect the motor lead connections at the motor terminal box and reconnect for proper rotation.

7. Check interlocking, control and instrument wiring for each system and/or part of a system to prove that the system will function properly as indicated by control schematic and wiring diagrams.

8. Verify all terminations at transformers, equipment, panels and enclosures by producing a 1, 2, 3 rotation on a phase sequenced motor when connected to "A," "B" and "C" phases.

9. Test the grounding system using the three-point fall in potential method.

10. Test all 600 Volt wire insulation with a meg-ohm meter after installation. Make tests at not less than 500V. Submit a written test report of the results to the Engineer.

11. Assist in the testing of the standby generator and automatic transfer switch. A licensed electrician shall be standing throughout the test perform make adjustments to or test the equipment furnished under this Division of the specifications and to open electrical enclosures.

D. Testing shall be scheduled and coordinated with the Owner at least two weeks in advance. Provide qualified test personnel, instruments and test equipment.

1.9 SIZE OF EQUIPMENT

A. Investigate each space in the structure through which equipment must pass to reach its final location. Coordinate shipping splits with the manufacturer to permit safe handling and passage through restricted areas in the structure.

B. The equipment shall be kept upright at all times during storage and handling. When equipment must be tilted for passage through restricted areas, brace the equipment to ensure that the tilting does not impair the functional integrity of the equipment.

1.10 RECORD DRAWINGS

A. As the work progresses, legibly record all field changes on a set of project contract drawings, hereinafter called the "record drawings."

B. Record drawings shall accurately show the installed condition of the following items:

1. One-line Diagram(s).

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Electrical 16020-6


2. Raceways and pullboxes. Routing of all raceways on plan drawings.

3. Conductor sizes and conduit fills.

4. Panel Schedule(s).

5. Control Wiring Diagram(s).

6. Underground raceway and duct bank routing.

7. Plan view, sizes and locations of switchgear, distribution transformers, substations, motor control centers and panelboards.

C. Submit a schedule of control wiring raceways and wire numbers, including the following information:

1. Circuit origin, destination and wire numbers.

2. Field wiring terminal strip names and numbers.

D. Submit the record drawings and the schedule of control wiring raceways and wire numbers (or the point-to-point connection diagram) to the Engineer.

1.11 EQUIPMENT INTERCONNECTIONS

A. Review shop drawings of equipment furnished under other Divisions of this Specification and prepare coordinated wiring interconnection diagrams or wiring tables. Submit copies of wiring diagrams or tables with Record Drawings.

B. Furnish and install all equipment interconnections.

1.12 MATERIALS AND EQUIPMENT

A. Materials and equipment shall be new.

B. Material and equipment of the same type shall be the product of one manufacturer and shall be UL listed.

C. Warrant all equipment furnished under Division 16 in accordance with LAWA General Conditions GC-65 and PR-27 Close out. Refer to individual equipment sections for additional warranty items.

1.13 EQUIPMENT IDENTIFICATION

A. Identify equipment (disconnect switches, separately mounted motor starters, control stations, etc.) furnished under Division 16 with the name of the equipment it serves. Motor control centers, control panels, panelboards, switchboards, switchgear, junction or terminal boxes, transfer switches, etc., shall have nameplate designations as shown on the Drawings.

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Electrical 16020-7


B. Nameplates shall be engraved, laminated plastic, not less than 1/16-in thick by 3/4-in by 2-1/2-in with 3/16-in high white letters on a black background.

C. Nameplates shall be screw mounted to NEMA 1 enclosures. Nameplates shall be bonded to all other enclosure types using an epoxy or similar permanent waterproof adhesive. Two-sided foam adhesive tape is not acceptable. Where the equipment size does not have space for mounting a nameplate the nameplate shall be permanently fastened to the adjacent mounting surface.

1.14 INTERPRETATION OF DRAWINGS

A. The drawings do not show conduit routing within structures. Coordinate the conduit installation with other trades and the actual supplied equipment.

B. Install each 3-phase circuit in a separate conduit unless otherwise shown on the Drawings.

C. Where circuits are shown as "home-runs" all necessary fittings and boxes shall be provided for a complete raceway installation. Unless otherwise indicated install the conduits either concealed in the floor slab or under the floor slab in a slurry mix.

D. Verify the exact locations and mounting heights of lighting fixtures, switches and receptacles prior to installation.

E. Except where dimensions are shown, the locations of equipment, fixtures, outlets and similar devices shown on the Drawings are approximate only. Exact locations shall be determined by the Contractor and approved by the Engineer during construction. Obtain information relevant to the placing of electrical work and in case of any interference with other work, proceed as directed by the Engineer and furnish all labor and materials necessary to complete the work in an approved manner.

F. Redesign of electrical or mechanical work, which is required due to the Contractor's use of an alternate item, arrangement of equipment and/or layout other than specified herein, shall be done by the Contractor at his/her own expense. Redesign and detailed plans shall be submitted to the Engineer for approval. No additional compensation will be provided for changes in the work, either his/her own or others, caused by such redesign.

G. It is the intent of these Specifications that the Electrical Systems shall be suitable in every way for the service required. All materials and all work that may be implied as being incidental to the work of this Section shall be furnished at no additional cost to the Owner.

H. Raceways and conductors for lighting, switches, receptacles and other miscellaneous low voltage power and signal systems as specified are not shown on the drawings. Raceways and conductors shall be provided as required for a complete and operating system. Raceways shall be installed concealed in all finished spaces and may be installed exposed or concealed in all process spaces. Raceways installed exposed shall be near the ceiling or along walls of the areas through which they pass and shall be routed to avoid conflicts with HVAC ducts, cranes hoists, monorails, equipment

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hatches, doors, windows, etc. Raceways installed concealed shall be run in the center of concrete floor slabs, under concrete floor slabs in a slurry mix, above suspended ceilings, or in partitions as required.

I. Provide separate neutral conductors for each lighting branch circuit and outlet branch circuit.

1.15 SEISMIC RESTRAINTS

A. Seismic restraints shall be provided for all electrical systems including but not limited to conduits, busways, cable trays, pull boxes, free standing or wall mounted panels and cabinets, motor control centers, switchboards, switchgear, transformers, disconnect switches, individually mounted motor starters, variable frequency drives, power factor correction capacitors, lighting fixtures, emergency battery units and other similar electrical equipment installed under Division 16.

B. Use seismic criteria, Tables and standard restraint details found in the latest edition of the SMACNA Seismic Retraining Manual for the seismic restraints. The restraints shall be selected from the Tables that represent the highest seismic hazard class or level possible within the State, Commonwealth or District in which the project resides. Where materials other than steel are specified, members of equal strength to those in the standards shall be provided.

C. Materials of construction for seismic restraints shall be same as those specified for the equipment supports and area classifications. However, all bolts shall be stainless steel regardless of the locations.

PART 2 PRODUCTS

2.1 CONDUITS AND FITTING

A. Rigid Steel Conduit

1. Rigid steel conduit interior and exterior shall be hot-dipped galvanized and be as manufactured by the Allied Tube and Conduit Corp.; Wheatland Tube Co.; Western Tube & Conduit Corporation, or equal.

B. Rigid Nonmetallic Conduit

1. PVC conduit shall be rigid polyvinyl chloride schedule 40 and 80 as manufactured by Carlon; An Indian Head Co.; Kraloy Products Co., Inc.; Highland Plastics Inc., or equal.

C. Liquidtight Flexible Metal Conduit, Couplings and Fittings

1. Liquidtight flexible metal conduit shall be Sealtite, Type UA, manufactured by the Anaconda Metal Hose Div.; Anaconda American Brass Co.; American Flexible Conduit Co., Inc.; Universal Metal Hose Co., or equal.

2. Fittings used with liquidtight flexible metal conduit shall be of the screw-in type as manufactured by the Thomas & Betts Co.; Crouse-Hinds Co., or equal.

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D. Boxes and Fittings

1. Pressed steel switch and outlet boxes shall be hot-dipped galvanized as manufactured by the Raco Manufacturing Co.; Adalet Co.; O.Z. Manufacturing Co., or equal.

2. For use in NEMA 1 areas, terminal boxes, junction boxes, pull boxes etc, shall be galvanized sheet steel with continuously welded seams. Box bodies shall be flanged and shall not have holes or knockouts. Box bodies shall not be less than 14-gauge metal and covers shall not be less than 12 gauge metal. Covers shall be gasketed and fastened with stainless steel screws. Terminal boxes shall be furnished with hinged doors, terminal mounting straps and brackets. Terminal blocks shall be NEMA type, not less than 20 Amps, 600 Volt. Boxes shall be as manufactured by Hoffman Engineering Co.; Lee Products Co.; Keystone/Rees, Inc., or equal.

3. NEMA 4 terminal boxes, junction boxes, pull boxes, etc, shall be sheet stainless steel unless otherwise shown on the Drawings. Boxes shall have continuously welded seams and mounting feet. Welds shall be ground smooth. Boxes shall be flanged and shall not have holes or knockouts. Box bodies shall not be less than 14-gauge metal and covers shall not be less than 12 gauge metal. Covers shall have a continuous gasket on all four sides and be fastened with stainless steel clamps. Terminal boxes shall be furnished with hinged doors, terminal mounting straps and brackets. Terminal blocks shall be NEMA type, not less than 20 Amp, 600 Volt. Boxes shall be as manufactured by Hoffman Engineering Co.; Lee Products Co.; Keystone/Rees, Inc., or equal.

4. NEMA 4X terminal boxes, junction boxes and pull boxes shall be fiberglass reinforced plastic with stainless steel hardware and covers having a continuous gasket on all four sides. Terminal boxes shall be furnished with hinged doors, terminal mounting straps and brackets. Terminal blocks shall be NEMA type, not less than 20 Amps, 600 Volt. Boxes shall be as manufactured by Hoffman Engineering Co.; Lee Products Co.; Keystone/Rees, Inc., or equal.

5. Cast or malleable iron device boxes shall be Type FD. All cast or malleable iron boxes and fittings shall have cadmium-zinc finish with cast covers and stainless steel screws as manufactured by the Crouse-Hinds Co. or equal.

6. Cast aluminum device boxes shall be Type FD. All cast aluminum boxes and fittings shall be copper-free aluminum with cast aluminum covers and stainless steel screws as manufactured by the Killark Electric Co.; Crouse-Hinds Co.; L. E. Mason Co. or equal.

7. Steel elbows and couplings shall be hot-dipped galvanized.

8. Conduit hubs shall be as manufactured by Myers Electric Products, Inc. or equal.

9. Conduit wall and floor seals for sleeved openings shall be type CSMI as manufactured by the O.Z./Gedney Co.; or equal.

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10. Conduit sealing bushings shall be O.Z./Gedney Type CSB or equal.

11. Combination expansion-deflection fittings embedded in concrete shall be Type XD as manufactured by Crouse-Hinds Co.; Type AXDX as manufactured by O.Z./Gedney Co. Type DF as manufactured by Appleton Electric Co., or equal.

12. Combination expansion-deflection fittings installed exposed shall be Type XD as manufactured by Crouse-Hinds Co.; Type AXDX as manufactured by O.Z./Gedney Co. Type DF as manufactured by Appleton Electric Co., or equal.

13. Hazardous (Classified) Location Boxes:

a. Explosion-proof boxes shall be designed for Class 1, Group D, Division 1 hazardous locations. They shall be cast iron with cadmium-zinc or hot-dipped galvanized finish, stainless steel or hot-dipped galvanized bolts; Type EJB as manufactured by the Crouse-Hinds Company; Appleton Electric Co.; The Pyle-National Co., or equal.

E. Miscellaneous Fittings:

1. Flexible couplings shall be type ECGJH as manufactured by the Crouse-Hinds Co.; Appleton Electric Co.; Killark Electric Manufacturing Co. or equal.

2. Conduit hubs shall be as manufactured by Myers Electric Products, Inc. or equal.

3. Conduit wall and floor seals for sleeved openings shall be Type CSMI as manufactured by the O.Z./Gedney Co., or equal.

4. Combination expansion-deflection fittings embedded in concrete shall be Type XD as manufactured by the Crouse-Hinds Co.; Type DX as manufactured by O.Z./Gedney Co.; Type DF as manufactured by Appleton Electric Co., or equal.

5. Explosion proof fittings shall be as manufactured by the Crouse-Hinds Co.; Appleton Electric Co.; O.Z./Gedney Co., or equal.

6. Conduit sealing bushings shall be O.Z./Gedney, Type CSB, or equal.

7. Grounding bushings shall be malleable iron with integral insulated throat rated for 150 degrees C, with solderless lugs as manufactured by Crouse Hinds/Cooper, Series HGLL; Appleton, Series GIB; O.Z./Gedney, Type HBLG, or equal.

F. Conduit Mounting Equipment

1. In dry indoor areas, hangers, rods, backplates, beam clamps, channel, etc. shall be galvanized iron or steel.

2. Stainless steel with stainless steel hardware shall be used in the pump room. Fiberglass channel shall be used in the chemical room.

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G. Wall and Floor Slab Opening Seals

1. Wall and floor slab openings shall be sealed with "FLAME-SAFE" as manufactured by the Thomas & Betts Corp.; Pro Set Systems; Neer Mfg. Co.; Specified Technologies, Inc., or equal.

H. Cold Galvanizing Compound

1. Cold galvanizing compound shall be as manufactured by ZRC Products Company, a division of Norfolk Corp., or equal.

2.2 WIRE, CABLE AND ACCESSORIES

A. Wires and cables shall be of annealed, 98 percent conductivity, soft drawn copper.

B. All conductors shall be stranded, except that lighting and receptacle wiring may be solid.

C. Except for control, signal and instrumentation circuits, wire smaller than No. 12 AWG shall not be used.

D. Wire for circuits over 150 Volts to ground shall be NEC type XHHW-2 as manufactured by Okonite Co.; Southwire Co., or equal.

E. Wire for control, status and alarm circuits shall be No.14 AWG NEC type THHN/THWN-2, stranded as manufactured by the Okonite Co.; Carol Cable Co. Inc. West; Pirelli Cable Corp., or equal.

F. Wire for process instrumentation signals (i.e., 1-5 VDC, 4-20 mA), R.T.D., potentiometer and similar signals shall be:

1. Single pair cable:

a. Conductors: 2- No.18 stranded and twisted on 2-in lay

b. Insulation: PVC with 300 Volt, 105 degrees C rating

c. Shield: 100 percent Mylar tape with drain wire

d. Jacket: PVC with UL Subject 13, UL 1581, and manufacturer's identification

e. Max overall diameter: 0.262-in

f. Miscellaneous UL listed for underground wet location use g. Manufacturers: Belden No. 1030, or equal

2. Three conductor (triad) cable:

a. Conductors: 3- No.18 stranded and twisted on 2-in lay

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b. Insulation: PVC with 300 Volt, 105 degrees C rating

c. Shield: 100 percent Mylar tape with drain wire

d. Jacket: PVC with UL Subject 13, UL 1581 and manufacturer's identification

e. Max overall diameter: 0.276-in

f. Miscellaneous: UL listed for underground wet location use

g. Manufacturers: Belden No. 1031, or equal

G. Splices for power wiring shall be compression type connectors insulated with a heat

shrink boot or outer covering and epoxy filling. Splice kits shall be as manufactured by Raychem; Ideal Industries; 3M Co., or equal.

H. Motor connections shall be ring type mechanical compression terminations installed on the branch circuit wires and the motor leads and secured with bolt, nut and springwasher. Connections shall be insulated with a Raychem Type RVC, roll-on stub insulator, or equal.

I. Termination connectors for control wiring shall be of the locking fork-end (upturned leg ends) type as manufactured by Ideal Industries; 3M Co.; Panduit Corp. or equal.

J. Splices for control wiring shall be insulated compression type connectors of the expanded vinyl insulated parallel or pigtail type as manufactured by Ideal Industries; 3M Co.; Panduit Corp. or equal.

K. Termination connectors for shielded instrumentation wiring shall be of the locking fork- end (upturned leg ends) type as manufactured by Ideal Industries; 3M Co.; Panduit Corp., or equal.

L. Wire markers shall be "Omni-Grip" as manufactured by the W.H. Brady Co.; Thomas & Betts Co.; 3M Co., or equal.

M. Wire and cables with diameters exceeding the capacity of the "Omni-Grip" shall be marked with pre-printed, self-adhesive vinyl tapes as manufactured by the W.H. Brady Co.; Panduit Corp., or equal.

N. Direct buried cable warning tape shall be 6-in wide, red polyethylene not less than 0.0035-in thick. Tape shall be W.H. Brady Co., Catalog No. 91296, or equal.

2.3 WIRING DEVICES

A. Device Plates

1. Plates for indoor flush mounted devices shall be of the required number of gangs for the application involved and shall be as follows:

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a. Where permitted in other areas of the plant, flush mounted devices in cement block construction shall be Type 302 high nickel (18-8) stainless steel of the same manufacturer as the devices.

2. Plates for indoor surface mounted device boxes shall be cast metal of the same material as the box, Crouse-Hinds, No. DS23G and DS32G, or equal.

3. Oversized plates shall be installed where standard plates do not fully cover the wall opening.

4. Device plates for switches mounted outdoors or indicated as weatherproof shall be gasketed, cast aluminum with provisions for padlocking switches "On" and "Off," Crouse Hinds, No. DS185, or equal.

5. Multiple surface mounted devices shall be ganged in a single, common box and provided with an adapter, if necessary, to allow mounting of single gang device plates on multigang cast boxes.

6. Engraved device plates shall be provided where required.

7. Weatherproof, gasketed cover for GFI receptacle mounted in a FS/FD box shall be Arrow-Hart, Catalog No. 4501-FS or equal by Harvey Hubbell, Inc.; Pass & Seymour, Inc., or equal.

2.4 SWITCHBOARDS:

A. Products of the following manufacturers are acceptable:

1. Eaton / Cutler-Hammer

2. General Electric

3. Square D

4. Or equal.

B. Buses:

1. Buses: non-tapered, tin-plated copper. Provide a fully rated neutral bus where a neutral bus is indicated on the Drawings.

2. Bus bracing: exceed the specified equipment short circuit current rating, but not less than 42,000 amperes RMS symmetrical.

3. Bus joints: welded connections or accessible bolted joints with high-tensile strength, zinc-plated hardware and conical spring-type washers.

4. Ground bus: provide a copper ground bus extending throughout the entire length of the switchboard, firmly secured to each vertical section structure and equipped with lugs for external ground connections, sized for cables shown on the Drawings.

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C. EQUIPMENT:

1. Switchboard shall consist of the required number of vertical sections bolted together to form a rigid assembly. The sides and rear shall be covered with removable bolt-on covers. All edges of front covers or hinged front panels shall be formed. Provide adequate ventilation within the enclosure.

2. All sections of the switchboard shall be rear aligned with depth as shown on the drawings. Devices shall be front removable and load connections front accessible enabling switchboard to be mounted against a wall. Side access shall not be required. All connections and bus maintenance shall be from the front or the top.

3. Enclosure:

a. NEMA 4X enclosure consisting of side, top and rear covers bolted to steel frame structure members. Front doors shall be hinged and gasketed with captive quarter turn fasteners.

4. Utility Metering:

a. Where utility metering is indicated on the Drawings, furnish a separate barriered utility metering compartment complete with hinged sealable door. Bus work shall include provisions for mounting utility company current transformers and potential transformers or potential taps as required by the utility company. Provide service entrance label and provide necessary applicable service entrance features per NEC and local code requirements.

b. A cable pull section shall be furnished.

5. Customer Metering:

a. Where indicated on the drawings, provide a separate customer metering compartment with a front facing hinged door and include the following: 1) Current transformers for each meter. Current transformers shall be wired to

shorting-type terminal blocks. 2) Potential transformers including primary and secondary fuses with

disconnecting means for metering as shown on the Drawings.

6. Main Section:

a. Main section: consists of an incoming cable compartment with main lugs or a main disconnecting device as shown on the Drawings.

b. Main breaker: individually mounted, drawout insulated-case circuit breaker as

indicated on the Drawings

7. Distribution Sections:

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2.5 THE DISTRIBUTION SECTIONS SHALL CONSIST OF INDIVIDUALLY MOUNTED MOLDED-CASE CIRCUIT BREAKERS AS INDICATED. FEEDER SECTIONS SHALL BE ISOLATED FROM MAIN SECTION, AND FROM ADJACENT FEEDER SECTIONS. FEEDER DEVICES SHALL BE MOUNTED IN INDIVIDUAL COMPARTMENTS WITH AN EXTERNAL OPERATING HANDLE LOCATED ON THE COMPARTMENT DOOR. MISCELLANEOUS EQUIPMENT

A. Disconnect Switches

1. Disconnect switches shall be heavy-duty, quick-make, quick-break, visible blades, 600 Volt, 3 Pole with full cover interlock, interlock defeat and flange mounted operating handle.

2. Switches shall be as manufactured by the Square D Co.; Cutler Hammer Co.; General Electric Company; Siemens Company, or equal.

B. Fused Disconnect Switches

1. Fused disconnect switches shall be heavy-duty, quick-make, quick-break, visible blades, 600 Volt, 3 Pole with full cover interlock, interlock defeat and flange mounted operating handle.

2. Fuses shall be rejection type, 600 Volt, 200,000 A.I.C., dual element, time delay, Bussman Fusetron, Class RK-5; Gould Shawmut Inc.; Littelfuse Power Fuse Division, or equal.

3. Switches shall be as manufactured by the Square D Co.; Cutler Hammer Co.; General Electric Company; Siemens Company, or equal.

C. Solid State Reduced Voltage Starters

1. Reduced voltage starters: where shown on the Drawings, provide UL and CSA listed solid-state, separately enclosed, reduced-voltage starters, consisting of an SCR-based power section, logic board and paralleling bypass contactor. Starters shall be sized for continuous operation up to a maximum of 115% of the connected motor full load ampere rating. All the components shall be contained in a NEMA 4X, non-walk-in enclosure.

2. Power section: six back-to-back SCRs rated for a minimum peak inverse voltage rating of 1500 volts PIV. Resistor/capacitor snubber networks shall prevent false firing of SCRs from dV/dT effects.

3. Logic board: identical for all ampere ratings and voltage classes with quick disconnect plug-in connectors for current transformer inputs, line and load voltage inputs and SCR gate firing output circuits for ease of testing, service and replacement.

4. Run bypass contactor: intelligent type motor controller to limit contact bounce and optimize coil voltage during varying system conditions, energized when the motor reaches 90% of full speed and close/open under one times motor current.

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5. Overload protection: electronic overload protection based on inverse time-current algorithm, capable of being disabled during ramp start for long acceleration loads. Overload protection adjustments via the device keypad shall include:

a. Motor full load ampere adjustment from 30 to 100% of the maximum

continuous ampere rating of the starter

b. Selectable overload class setting of 5, 10, 20 or 30

c. Electronic or mechanical reset capability after a fault

6. Provide the following protection features enabled from the device keypad

a. Heat sink over-temperature protection.

b. Improper line-side phase rotation shut down if a line-side phase rotation other than A-B-C exists.

c. Phase loss or unbalance condition shut down if a 50% current differential

between any two phases is encountered.

d. Motor stall protection.

e. Motor jam protection.

7. Alarm contacts: Form C normally open (NO), normally closed (NC) contacts shall change state when a fault condition exists and an LED display on the device keypad shall indicate type of fault.

8. Provide the following control function adjustments on the device keypad:

a. Selectable Torque Ramp Start or Current Limit Start

b. Adjustable Kick Start Time

c. Adjustable Kick Start Torque

d. Adjustable Ramp Start Time

e. Adjustable Initial Starting Ramp Torque

f. Adjustable Smooth Stop Ramp Time

9. Pump Control Option: Provide a factory installed control algorithm for pump startup and shutdown sequences to reduce the potential for water hammer in a centrifugal pump system. Upon a start command, the soft starter microprocessor ramps the speed of the motor to achieve a gentle start. The bypass contactors close after the speed reaches its nominal value. Upon a stop command, the bypass contactors are opened and the motor speed shall be decreased in a tapered manner to

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gradually slow the flow until the motor is brought to a stop. The start and stop ramp times shall be user adjustable and shall be set for the application requirements.

Digital interface module: door mounted display used to program the soft starter and monitor parameters including line currents, pole currents, pole voltages, number of starts, and DC control voltage. Soft starter shall display motor status and the previous five fault conditions.

D. Circuit Breakers

1. Provide thermal magnetic circuit breaker in NEMA Type Enclosure with externally operated handle. Circuit breakers shall be fully rated for 65,000 Amps RMS symmetrical.

2. Circuit breakers shall be manufactured by Cutler Hammer Co.; General Electric Company; Siemens Company, or equal.

E. Control Stations

1. Control stations shall be heavy-duty type, with full size operators. Momentary contact stop buttons shall have a lockout latch that can be padlocked in the open position.

2. Control stations shall be Square D Class 9001; Cutler Hammer Co.; General

Electric Company; Allen Bradley Company, or equal.

F. Control Relays

1. Control relays shall be ice cube type with an octal base, with 10 amp contacts. Number of contacts and coil voltage shall be as shown on the Drawings. General use relays shall be General Electric Co., Square D Co., Allen-Bradley Co. or equal.

G. Polyethylene Warning Tape

1. Warning tape shall be red polyethylene film, 6-in minimum width.

2. Warning tape shall be W.H. Brady Co., Catalog No. 91296, or equal.

H. On-Delay, Off-Delay Timers (Solid State)

1. On and off delay timers shall be microprocessor based, solid state type.

2. Timers shall have the following features:

a. Adjustable timing ranges from 0.1 seconds to 99 hours, 59 minutes minimum.

b. Setpoints entered by pressing membrane covered keyboard on unit.

c. LCD readout of timing progress and setpoint.

d. Adjustable for on-delay or off-delay modes.

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e. Standard sized plug-in case.

f. Totally sealed face plate.

g. Sealed battery backup power to retain memory for up to 30 days.

h. Accuracy plus or minus 0.01 second.

i. DPDT isolated instantaneous and timed output contacts rated 6 amps minimum at 120 Volt.

3. Timers shall be Bulletin 651 Multirange, solid state as manufactured by Tenor Co., Inc.; Eagle Signal CS-300 Series, or equal.

I. Equipment Mounting Stands

1. Equipment mounting stands shall be custom fabricated from 1/4-inch steel plate and 4-inch steel channel, as shown on the Drawings.

2. Hot dip galvanizing shall conform to the requirements of Division 5. 2.6 UNDERGROUND SYSTEM

A. Excavation and backfilling, including gravel and sand bedding, are included in Division 2.

B. All concrete shall be as specified in Division 3, but the responsibility of furnishing and installing the material shall be that of this Section.

C. All trenching and surface restoration shall be as specified in Division 2, but the responsibility of furnishing and installing the material shall be that of this Section.

D. Raceways shall be polyvinyl chloride conduit encased in concrete except that rigid steel conduit shall be used for shielded wire.

E. Handholes shall be precast concrete, heavy-duty type, designed for a Class H-20- wheel load and conform to ASTM C478. Precast units shall be as manufactured by Chase Precast Corp.; American Precast Co., or equal and constructed to dimensions as shown on the Drawings.

F. Handhole frames and covers shall be cast iron, heavy duty type for Class H-20-wheel loading.

2.7 GROUNDING

A. Ground rods shall be 3/4-in by 10-ft copper clad steel and constructed in accordance with UL 467. The minimum copper thickness shall be 0.25 mm. Ground rods shall be Copperweld, or equal.

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B. Grounding conduit hubs shall be malleable iron type similar to Thomas & Betts Co.; Cat No. 3940 (3/4-in conduit size) by Burndy; O.Z./Gedney Co., or equal, and of the correct size for the conduit.

C. Waterpipe ground clamps shall be cast bronze saddle type, similar to Thomas & Betts Co. Cat. No. 2 (1/2-in, 3/4-in, or 1-in size) or equal by Burndy; O.Z./Gedney Co. or equal, and of the correct size for the pipe.

D. Buried grounding connections shall be by Cadweld process, or equal exothermic welding system.

2.8 RUBBER FLOOR MATS

1. Furnish and install a non-conductive elastomer compound rubber floor mat extending the full length and placed in front of and in back of each 15-kV switchgear, each 480-volt switchgear/transformer and load break switch, and in front of each motor control center panelboards and separately mounted motor starters.

2. Mats shall be in accordance with ASTM D178, Type II, Class 2, 1/4-inch thick minimum, 36-inch wide with corrugated surface and shall be branded continuously on the back.

3. Mats shall have the following ratings: a. Voltage phase to phase 17,000 V RMS b. AC Proof Test Voltage 20,000 V RMS c. DC Proof Test Voltage 50,000 V Average

4. Type II mats shall be ozone, flame and oil resistant.

5. Install mats in one continuous piece. Where equipment faces each other, and is less than 6-feet apart, provide one width of mat.

6. Mats shall be stored without distortion, free from direct sun light or sources of ozone and at a temperature not to exceed 95 degrees F (35 degrees C).

PART 3 EXECUTION

3.1 SLEEVES AND FORMS FOR OPENINGS

A. Provide and place all sleeves for conduits penetrating floors, walls, partitions, etc. Locate all necessary slots for electrical work and form before concrete is poured.

B. Exact locations are required for stubbing-up and terminating concealed conduit. Obtain shop drawings and templates from equipment vendors or other subcontractors and locate the concealed conduit before the floor slab is poured.

C. Where setting drawings are not available in time to avoid delay in scheduled floor slab pours, the Engineer may allow the installations of such conduit to be exposed. Requests for this deviation must be submitted in writing. No additional compensation for such change will be allowed.

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D. Seal all openings, sleeves, penetration and slots.

3.2 CUTTING AND PATCHING

A. Cutting and patching shall be done in a thoroughly workmanlike manner and be in compliance with modifications and repair to concrete as specified in other sections.

B. Core drill holes in concrete floors and walls as required.

C. Install work at such time as to require the minimum amount of cutting and patching.

D. Do not cut joists, beams, girders, columns or any other structural members.

E. Cut opening only large enough to allow easy installation of the conduit.

F. Patching to be of the same kind and quality of material as was removed.

G. The completed patching work shall restore the surface to its original appearance or better.

H. Patching of waterproofed surfaces shall render the area of the patching completely waterproofed.

I. Remove rubble and excess patching materials from the premises.

J. When existing conduits are cut at the floor line of wall line, they shall be filled with grout of suitable patching material.

3.3 INSTALLATION

A. Any work not installed according to the Specifications shall be subject to change as directed by the Engineer. No extra compensation will be allowed for making these changes.

B. Electrical equipment shall be protected at all times against mechanical injury or damage by water. Electrical equipment shall not be stored outdoors. Electrical equipment shall be stored in dry permanent shelters. Do not install electrical equipment in its permanent location until structures are weather-tight. If any apparatus has been subject to possible injury by water, it shall be thoroughly dried out and tested as directed by the Engineer, or shall be replaced at no additional cost at the Engineer's discretion.

C. Equipment that has been damaged shall be replaced or repaired by the equipment manufacturer, at the Engineer's discretion.

D. Repaint any damage to factory applied paint finish using touch-up paint furnished by the equipment manufacturer. The entire damaged panel or section shall be repainted per the field painting specifications in Section 09902, at no additional cost to the Owner.

E. Coordinate the conduit installation with other trades and the actual supplied equipment.

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F. Install each 3-phase circuit in separate conduit.

G. In general conduit installed interior to the pump station shall be ran in a slurry mix under the floor slab or concealed in the floor slab and stub up on both ends at the equipment. Exposed conduit shall be installed for lighting, bridge crane, and low voltage systems.

H. Verify the exact locations and mounting heights of lighting fixtures, switches and receptacles prior to installation.

I. Exact locations of electrical equipment shall be determined by the Contractor and approved by the Engineer during construction. Obtain information relevant to the placing of electrical work and in case of any interference with other work, proceed as directed by the Engineer and furnish all labor and materials necessary to complete the work in an approved manner.

3.4 MANUFACTURERS SERVICE

A. Provide manufacturer's services for testing and start-up and training of the following equipment:

1. 480 Volt Switchboards (2 days, 1trip minimum)

B. Testing and startup shall not be combined with training. Testing and start-up time shall not be used for manufacturer’s warranty repairs.

3.5 BOXES AND FITTINGS

A. Except where otherwise specified, all wiring shall be in rigid steel conduit.

B. Rigid steel conduit shall be used at all locations (underground and within structures) as raceways for shielded process instrumentation wiring, shielded control wiring, and I/O wiring.

C. PVC conduit shall be used for concrete encased underground duct banks except as specified in Paragraph 3.05B above.

D. All boxes shall be metal.

E. Terminal boxes, junction boxes and pull boxes shall have NEMA ratings suitable for the location in which they are installed.

F. Conduit sealing bushings shall be used to seal conduit ends exposed to the weather.

G. No conduit smaller than 3/4-inch electrical trade size shall be used, nor shall any have more than the equivalent of three 90-degree bends in any one run. Pull boxes shall be provided as required or directed.

H. No wire shall be pulled until the conduit system is complete in all details.

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I. The ends of all conduits shall be tightly plugged to exclude dust and moisture during construction.

J. Conduit supports, other than for underground raceways, shall be spaced at intervals of 8-ft or less.

K. Conduit hangers shall be attached to structural steel by means of beam or channel clamps. Where attached to concrete surfaces, concrete inserts of the spot type shall be provided.

L. All conduits shall be run at right angles to and parallel with the surrounding wall and shall conform to the form of the ceiling. No diagonal runs will be allowed. Bends in parallel conduit runs shall be concentric. All conduits shall be run perfectly straight and true.

M. Conduit terminating in pressed steel boxes shall have double locknuts and insulated bushings.

N. Conduit terminating in NEMA 3R, 4, 4X and 12 enclosures shall be terminated with Myers type conduit hubs.

O. Conduits containing equipment grounding conductors and terminating in sheet steel boxes shall have insulated throat grounding bushings.

P. Conduits shall be installed using threaded fittings.

Q. Liquidtight flexible metal conduit shall be used for all motor terminations, the primary and secondary of transformers, generator terminations and other equipment where vibration is present.

R. Flexible couplings shall be used in hazardous locations for all motor terminations and other equipment where vibration is present.

S. Where conduits pass through openings in walls or floor slabs, the remaining openings shall be sealed against the passage of flame and smoke.

T. PVC conduit to non-metallic box connections shall be made with PVC socket to male thread terminal adapters with neoprene O-ring and PVC round edge bushings.

U. Conduit ends exposed to the weather shall be sealed with conduit sealing bushings.

V. PVC conduit shall be supported with non-metallic clamps, non-metallic racks, and stainless steel hardware.

W. PVC boxes, conduit fittings, etc. with integral hubs shall be solvent welded directly to the PVC conduit system.

X. Non-metallic boxes with field drilled or punched holes shall be connected to the PVC conduit system with threaded and gasketed PVC Terminal Adapters.

Bid Set April 2017

Electrical 16020-23


Y. All conduit entering or leaving a motor control center, switchboard or other multiple compartment enclosure shall be stubbed up into the bottom horizontal wireway or other manufacturer designated area, directly below the vertical section in which the conductors are to be terminated.

Z. All conduit which may under any circumstance contain liquids such as water,

condensation, liquid chemicals, etc, shall be arranged to drain away from the equipment served. If conduit drainage is not possible, conduit seals shall be used to plug the conduits.

AA. Where no type or size is indicated for junction boxes, pull boxes or terminal cabinets, they shall be sized in accordance with the requirements of N.E.C. Article 370.

BB. Miscellaneous steel for the support of fixtures, boxes, transformers, starters, contactors, panels and conduit shall be furnished and installed.

CC. Conduits passing from heated to unheated spaces, exterior spaces, refrigerated spaces, cold air plenums, etc., shall be sealed with "Duxseal" as manufactured by Manville or seal fitting to prevent the accumulation of condensation.

DD. Rigid galvanized steel conduits which have been field cut and threaded shall be painted with cold galvanizing compounds.

EE. Conduit expansion and deflection fittings shall be installed on all conduits crossing building expansion joint. Where conduits are installed outdoors provide expansion and deflection fittings on all conduits crossing expansion joints or at 200 foot intervals whichever is the least dimension.

3.6 WIRE, CABLE AND ACCESSORIES

A. Uniquely identify all wires, cables and each conductor of multi- conductor cables (except lighting and receptacle wiring) at each end with wire and cable markers.

B. Use lubrications to facilitate wire pulling. Lubricants shall be UL approved for use with the insulation specified.

C. All wire shall be color coded or coded using electrical tape in sizes where colored insulation is not available. Where tape is used as the identification system, it shall be applied in all junction boxes, and other accessible intermediate locations as well as at each termination.

D. The following coding shall be used:

System Wire Color

240/120 Volts Neutral White 1-Phase, 3-Wire Line 1 Black Line 2 Red 480Y/277 Volts Neutral White

Bid Set April 2017

Electrical 16020-24


System Wire Color

3-Phase, 4-Wire Phase A Brown Phase B Orange Phase C Yellow

E. Power conductors: Terminations shall be die type or set screw type pressure connectors as specified. Splices (where allowed) shall be die type compression connector and waterproof with heat shrink boot or epoxy filling. Aluminum conductors (where specified) shall employ terminations and splices specifically designed for aluminum conductors.

F. Control Conductors: Termination on saddle-type terminals shall be wired directly with a

maximum of two conductors. Termination on screw type terminals shall be made with a maximum of two spade connectors. Splices (where allowed) shall be made with insulated compression type connectors.

G. Instrumentation Signal Conductors (including graphic panel, alarm, low and high level signals): terminations same as for control conductors. Splices allowed at instrumentation terminal boxes only.

H. Except where permitted by the Engineer no splices will be allowed in manholes, handholes or other below grade located boxes.

I. Splices shall not be made in push button control stations, control devices (i.e., pressure switches, flow switches, etc.), conduit bodies, etc.

J. Instrumentation cables shall be installed in rigid steel raceways as specified. All circuits shall be installed as twisted pairs or triads. In no case shall a circuit be made up using conductors from different pairs or triads. Triads shall be used wherever three wire circuits are required.

K. Terminal blocks shall be provided at all instrument cable junction and all circuits shall be identified at such junctions.

L. Shielded instrumentation wire, shall be run without splices between instruments, terminal boxes, or panels.

M. Shields shall be grounded as recommended by the instrument manufacturer and isolated at all other locations. Terminal blocks shall be provided for inter-connecting shield drain wires at all junction boxes. Where individual circuit shielding is required, each shield circuit shall be provided with its own block.

3.7 WIRING DEVICES

A. Switch and receptacles outlets shall be installed flush with the finished wall surfaces in areas with stud frame and gypboard construction, in dry areas with cement block construction or when raceways are concealed.

Bid Set April 2017

Electrical 16020-25


3.8 PANELBOARDS

A. Mount boxes for surface mounted panelboards so there is at least 1/2-in air space between the box and the wall.

B. Connect panelboard branch circuit loads so that the load is distributed as equally as possible between the phase busses.

C. Type circuit directories giving location and nature of load served. Install circuit directories in each panelboard.

D. Install markers on the front cover of all panelboards which identify the voltage rating. Markers shall be made of self-sticking B-500 vinyl cloth printed with black characters on an Alert Orange background, 2-1/4-inches high by 9-inches wide, Style A as manufactured by W.H. Brady Co., or equal.

E. Install a 1-inch by 3-inch laminated plastic nameplate with 1/4-inch white letters on a black background on each panelboard. Nameplate lettering shall be as shown on the Drawings. Nameplates shall be stainless steel screw mounted.

3.9 UNDERGROUND SYSTEM

A. Install raceways to drain away from buildings.

B. The minimum cover for raceway banks shall be 24-in unless otherwise permitted by the Engineer.

C. Swab all raceways clean before installing cable.

D. Plug spare raceways and seal them watertight at all manholes, buildings and structures.

E. Seal the ends of raceways and make watertight at all handholes, buildings and structures.

3.10 GROUNDING

A. Run grounding electrode conductors in rigid steel conduits. Bond the protecting conduits to the grounding electrode conductors at both ends. Do not allow water pipe connections to be painted. If the connections are painted, disassemble them and re- make them with new fittings.

B. Install equipment grounding conductors with all feeders and branch circuits.

C. Bond all steel building columns in new structures together with ground wire in rigid conduit and connect to the distribution equipment ground bus.

D. Ground wire connections to structural steel columns shall be made with long barrel type one-hole heavy duty copper compression lugs, bolted through 1/2-in maximum diameter holes drilled in the column web, with stainless steel hex head cap screws and nuts.

Bid Set April 2017

Electrical 16020-26


E. Metal conduits stubbed into a motor control center shall be terminated with insulated grounding bushings and connect to the motor control center ground bus. Bond boxes mounted below motor control centers to the motor control center ground bus. Size the grounding wire in accordance with NEC.

F. Liquid tight flexible metal conduit in sizes 1-1/2-inches and larger shall have bonding

jumpers. Bonding jumpers shall be external, run parallel (not spiraled) and fastened with plastic tie wraps.

G. Ground transformer neutrals to the nearest available grounding electrode with a conductor sized in accordance with NEC Article 250-94.

H. Seal exposed connections between different metals with No-Oxide Paint Grade A or equal.

I. Lay all underground grounding conductors slack and, where exposed to mechanical injury, protect by pipes or other substantial guards. If guards are iron pipe, or other magnetic material, electrically connect conductors to both ends of the guard. Make connections as specified herein.

J. Care shall be taken to ensure good ground continuity, in particular between the conduit system and equipment frames and enclosures. Where necessary, jumper wires shall be installed.

K. All grounding type receptacles shall be grounded to the outlet boxes with a No. 12 THW green conductor connected to the ground terminal of the receptacle and fastened to the outlet box by means of a grounding screw.

L. Test the grounding system. Resistance to ground testing shall be performed during dry season. Submit test results in the form of a graph showing the number of points measured (12 minimum) and the numerical resistance to ground.

M. Testing shall be performed before energizing the distribution system.

N. Notify the Engineer immediately if the resistance to ground for any building or system is greater than 25 ohms.

END OF SECTION

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